Polymeric netting of ribbons and strands and methods of making the same

ABSTRACT

A polymeric netting including polymeric ribbons and polymeric strands. Each of the polymeric ribbons and strands has a length and width, with the length being the longest dimension and the width being the shortest dimension. The polymeric ribbons have a height-to-width aspect ratio of at least five to one, a major surface that is intermittently bonded to only one polymeric strand, and a height greater than the height of the one polymeric strand. An extrusion die and method useful for making the polymeric netting are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/042,066, filed Aug. 26, 2014; 61/946,601, filed Feb. 28, 2014; and61/946,592, filed Feb. 28, 2014; the disclosures of which areincorporated by reference in their entirety herein.

BACKGROUND

Polymeric nets are used for a wide variety of applications, includingreinforcement of paper articles or inexpensive textiles (e.g., insanitary paper articles, paper cloth, and heavy duty bags), non-wovenupholstery fabrics, window curtains, decorative netting, wrappingmaterial, mosquito netting, protective gardening netting against insectsor birds, backing for growing of grass or plants, sport netting, lightfishing netting, and filter materials.

Extrusion processes for making polymeric nets are known in the art. Forexample, recently extrusion dies and methods using a plurality of shimshave been reported to be capable of producing polymeric netting having athickness up to 750 micrometers. The polymeric strands of the nettingare described as being periodically joined together at bond regionsthroughout the array. See Int. Pat. Appl. Pub. Nos. WO2013/028654,WO2013/032683, and WO2013/052371, each to Ausen et al. Also, an extrudedarticle including an undulating strand with an aspect ratio of at leastabout 2 to 1 is disclosed in U.S. Pat. No. 4,634,485 (Welygan et al.).

SUMMARY

The present disclosure provides a polymeric netting including at leasttwo different types of generally continuous elements, one of which isribbon like and oriented on its edge within the netting. The ribbon-likeelement can be at least partially held in place by a second element thathas a smaller height.

In one aspect, the present disclosure provides a polymeric nettingincluding polymeric ribbons and polymeric strands. Each of the polymericribbons and strands has a length and width, with the length being thelongest dimension and the width being the shortest dimension. Thepolymeric ribbons have a height-to-width aspect ratio of at least fiveto one, a major surface that is intermittently bonded to only onepolymeric strand, and a height that is at least two times greater thanthe height of the one polymeric strand. In some embodiments, thepolymeric ribbons are elastic, the polymeric strands are elastic, orboth the polymeric ribbons and the polymeric strands are elastic.

In another aspect, the present disclosure provides an absorbent articleincluding the polymeric netting described above.

In another aspect, the present disclosure provides the polymeric nettingdescribed above joined to a carrier.

In another aspect, the present disclosure provides the polymeric nettingdescribed above for use as an elastic wrap.

In another aspect, the present disclosure provides an absorbent article.The absorbent article includes a polymeric netting, a liquid impermeablebacksheet, and an absorbent core. The polymeric netting includespolymeric ribbons and polymeric strands. Each of the polymeric ribbonsand strands has a length and width, with the length being the longestdimension and the width being the shortest dimension. The polymericribbons have a height-to-width aspect ratio of at least three to one, amajor surface that is intermittently bonded to only one polymericstrand, and a height that is greater than the height of the onepolymeric strand. The absorbent core can be between the polymericnetting and the backsheet, the polymeric netting can be between theabsorbent core and the backsheet, or the polymeric netting can be withinthe absorbent core.

In embodiments of any of the foregoing aspects, typically each majorsurface of the polymeric ribbon is intermittently bonded to only onepolymeric strand.

In another aspect, the present disclosure provides an extrusion die. Theextrusion die includes at least one cavity, a dispensing surface, andfluid passageways between the at least one cavity and the dispensingsurface. The dispensing surface has an array of first dispensingorifices separated by an array of second dispensing orifices, and thefirst dispensing orifices, second dispensing orifices, and any otherdispensing orifices are arranged in a single row across the dispensingsurface. The first and second dispensing orifices each have a height anda width. The first dispensing orifices each have a height-to-widthaspect ratio of at least five to one, and the height of the firstdispensing orifices is at least three times larger than the height ofthe second dispensing orifices.

In another aspect, the present disclosure provides a method of making apolymeric netting. The method includes providing the aforementionedextrusion die. The method further includes dispensing polymeric ribbonsfrom the first dispensing orifices at a first speed while simultaneouslydispensing polymeric strands from the second dispensing orifices at asecond speed to provide the polymeric netting, wherein the first speedis at least twice the second speed, or wherein the second speed is atleast twice the first speed.

In another aspect, the present disclosure provides a method of making apolymeric netting. The method includes providing an extrusion diecomprising at least one cavity, a dispensing surface, and fluidpassageways between the at least one cavity and the dispensing surface.The dispensing surface has an array of first dispensing orificesseparated by an array of second dispensing orifices. The first andsecond dispensing orifices each have a height and a width. The firstdispensing orifices each have a height-to-width aspect ratio of at leastfive to one, and the height of the first dispensing orifices is at leasttwo times larger than the height of the second dispensing orifices. Themethod further includes dispensing polymeric ribbons from the firstdispensing orifices at a first speed while simultaneously dispensingpolymeric strands from the second dispensing orifices at a second speedthat is at least twice the first speed to provide the polymeric netting.

In this application, terms such as “a”, “an” and “the” are not intendedto refer to only a singular entity, but include the general class ofwhich a specific example may be used for illustration. The terms “a”,“an”, and “the” are used interchangeably with the term “at least one”.The phrases “at least one of” and “comprises at least one of” followedby a list refers to any one of the items in the list and any combinationof two or more items in the list. All numerical ranges are inclusive oftheir endpoints and non-integral values between the endpoints unlessotherwise stated (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and5).

The terms “first” and “second” are used in this disclosure. It will beunderstood that, unless otherwise noted, those terms are used in theirrelative sense only. In particular, in some embodiments certaincomponents may be present in interchangeable and/or identical multiples(e.g., pairs). For these components, the designation of “first” and“second” may be applied to the components merely as a matter ofconvenience in the description of one or more of the embodiments.However, when first and second edges are described, it should beunderstood that the first edges for a portion of polymeric ribbons areeach in the same orientation. For example, when looking at a polymericnetting, the first edges may be all those defining the upper surface ofthe polymeric netting, and the second edges may be all those definingthe lower surface of the polymeric netting, or vice versa.

The term “ribbon” refers to longitudinally extending elements in thepolymeric netting having a generally rectangular or oblong crosssection. There may be ribbons in the polymeric nettings disclosed hereinother than those having a height-to-width aspect ratio of at least threeto one, at least five to one, or at least seven to one. In other words,not all elements in the polymeric netting having rectangular crosssections are required to have a height-to-width aspect ratio of at leastthree to one, at least five to one, or at least seven to one. Thepolymeric strands may also have rectangular cross sections.

A major surface of the polymeric ribbons is a surface defined by theheight and the length of the ribbon.

The terms “multiple” and “a plurality” refer to more than one.

The term “netting” is used to describe the constructions herein sincethere are spaces between the ribbons and strands, for example, betweenthe sites where they are bonded together. Such spaces provide openingsin the netting.

The term “elastic” refers to any material (such as a film that is 0.002mm to 0.5 mm thick) that exhibits recovery from stretching ordeformation. In some embodiments, a material may be considered to beelastic if, upon application of a stretching force, it can be stretchedto a length that is at least about 25 (in some embodiments, 50) percentgreater than its initial length and can recover at least 40 percent ofits elongation upon release of the stretching force. “Elongation” interms of percent refers to {(the extended length−the initial length)/theinitial length} multiplied by 100.

The above summary of the present disclosure is not intended to describeeach disclosed embodiment or every implementation of the presentdisclosure. The description that follows more particularly exemplifiesillustrative embodiments. It is to be understood, therefore, that thefollowing description should not be read in a manner that would undulylimit the scope of this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be more completely understood in consideration of thefollowing detailed description of various embodiments of the disclosurein connection with the accompanying drawings, in which:

FIG. 1 is cross-sectional side view of an embodiment of a polymericnetting according to the present disclosure;

FIG. 2 is a perspective view of an embodiment of a polymeric nettingaccording to the present disclosure;

FIG. 3 is schematic cross-sectional view of a plane of anotherembodiment of a polymeric netting according to the present disclosure,in which the polymeric netting is joined to a substrate such as anabsorbent component;

FIG. 4 is schematic cross-sectional view of a plane of yet anotherembodiment of a polymeric netting according to the present disclosure;

FIG. 5 is schematic cross-sectional view of a plane of still anotherembodiment of a polymeric netting according to the present disclosure;

FIG. 6 is schematic cross-sectional view of a plane of still anotherembodiment of a polymeric netting according to the present disclosure;

FIG. 7 is schematic cross-sectional view of a plane of still anotherembodiment of a polymeric netting according to the present disclosure;

FIG. 8 is schematic cross-sectional view of a plane of yet anotherembodiment of a polymeric netting according to the present disclosure;

FIG. 9 is a plan view of an embodiment of a shim suitable for a sequenceof shims capable of forming a polymeric netting as shown, for example,in FIGS. 1 to 4;

FIG. 10 is a plan view of another embodiment of a shim suitable for asequence of shims capable of forming a polymeric netting as shown, forexample, in FIGS. 1 to 7;

FIG. 11 is a plan view of another embodiment of a shim suitable for asequence of shims capable of forming a polymeric netting as shown, forexample, in FIGS. 1 to 4;

FIG. 12A is a perspective assembly drawing of a sequence of shimsemploying the shims of FIGS. 9, 10, and 11 configured to form a portionof the polymeric netting as shown in FIG. 1;

FIG. 12B is an expanded view of the section referenced as “12B” in FIG.12A;

FIG. 13 is a plan view of an embodiment of a shim suitable for asequence of shims capable of forming a polymeric netting as shown, forexample, in FIG. 5;

FIG. 14 is a plan view of another embodiment of a shim suitable for asequence of shims capable of forming a polymeric netting as shown, forexample, in FIG. 5;

FIG. 15A is a perspective assembly drawing of a sequence of shimsemploying the shims of FIGS. 10, 13, and 14 configured to form a portionof the polymeric netting as shown in FIG. 5;

FIG. 15B is an expanded view of the section referenced as “15B” in FIG.15A;

FIG. 16 is a plan view of an embodiment of a shim suitable for asequence of shims capable of forming a polymeric netting as shown, forexample, in FIG. 6;

FIG. 17 is a plan view of another embodiment of a shim suitable for asequence of shims capable of forming a polymeric netting as shown, forexample, in FIG. 6;

FIG. 18A is a perspective assembly drawing of a sequence of shimsemploying the shims of FIGS. 10, 11, 16, and 17 configured to form aportion of the polymeric netting as shown in FIG. 6;

FIG. 18B is an expanded view of the section referenced as “18B” in FIG.18A;

FIG. 19 is a plan view of an embodiment of a shim suitable for asequence of shims capable of forming a polymeric netting as shown, forexample, in FIG. 7;

FIG. 20 is a plan view of another embodiment of a shim suitable for asequence of shims capable of forming a polymeric netting as shown, forexample, in FIG. 7;

FIG. 21A is a perspective assembly drawing of a sequence of shimsemploying the shims of FIGS. 10, 14, 19, and 20 configured to form aportion of the polymeric netting as shown in FIG. 7;

FIG. 21B is an expanded view of the section referenced as “21B” in FIG.21A;

FIG. 22 is an exploded perspective view of an example of a mountsuitable for an extrusion die composed of multiple repeats of thesequence of shims shown in FIG. 12A, 15A, 18A, 21A, or 27A;

FIG. 23 is a perspective view of the mount of FIG. 22 in an assembledstate;

FIG. 24 is a plan view of an embodiment of a shim suited to form asequence of shims useful for making a polymeric netting as shown, forexample, in FIG. 8;

FIG. 25 is a plan view of another embodiment of a shim suited to form asequence of shims useful for making a polymeric netting as shown, forexample, in FIG. 8;

FIG. 26 is a plan view of yet another embodiment of a shim suited toform a sequence of shims useful for a polymeric netting as shown, forexample, in FIG. 8;

FIG. 27A is a perspective drawing of a sequence of shims employing theshims of FIGS. 24 to 26 configured to form a portion of a polymericnetting as shown, for example, in FIG. 8;

FIG. 27B is an expanded view of the section referenced as “27B” in FIG.27A;

FIG. 28 is a schematic exploded view of an example of an absorbentarticle according to the present disclosure;

FIG. 29 is a perspective view of a foot showing an embodiment of thepolymeric netting according to the present disclosure used as a wrap;

FIG. 30 is a photograph of a top view of the polymeric netting ofExample 1;

FIGS. 31A and 31B are photographs of top and side views, respectively,of the polymeric netting of Example 2;

FIGS. 32A and 32B are photographs of top and side views, respectively,of the polymeric netting of Example 3;

FIGS. 33A and 33B are photographs of top and side views, respectively,of the polymeric netting of Example 4;

FIGS. 34A and 34B are photographs of top and side views, respectively,of the polymeric netting of Example 6; and

FIG. 35 is a photograph of a test jig used to evaluate the fluidstrike-through time for Examples 1, 1b, 4a, 4b, 6a, and 6b.

DETAILED DESCRIPTION

FIG. 1 illustrates a side view of an embodiment of a polymeric netting10 according to the present disclosure. The polymeric netting 10includes polymeric ribbons 1 and polymeric strands 3. The polymericribbons 1 and polymeric strands 3 each have a length, width “w1” and“w3”, and height “h1” and “h3”. The length of the polymeric ribbons 1and strands 3 is the longest dimension and is not shown in FIG. 1. Thewidth is the shortest dimension. The height “h1” of the ribbons and theheight “h3” strands is typically between the length and width of each,respectively. However, the strands 3 can also have heights “h3” that aresubstantially the same as their widths “w3”. For circular strands, theheight and width may both be referred to as diameter. Theheight-to-width aspect ratio of at least some the polymeric ribbons isat least three to one. In some embodiments, the height-to-width aspectratio of at least some of the polymeric ribbons is at least 5:1, 7:1,8:1, 10:1, 11:1, 15:1, 20:1, 30:1, or 40:1. The height of the polymericribbon is generally greater than that of the polymeric strands. In someembodiments, the height of each of the polymeric ribbons is at least 2,2.5, 3, 5, 10, or 20 times greater than the height of the singlepolymeric strand. The height of the polymeric ribbons may be in a rangefrom 50 micrometers to 3 millimeters (mm). In some embodiments, theheight of the polymeric ribbons is greater than 750 micrometers. In someof these embodiments, the height of the polymeric ribbons is in a rangefrom greater than 750 micrometers to 3 mm (e.g., 0.775 mm to 2 mm or 0.8mm to 1.5 mm). In some embodiments, the height of at least one of thepolymeric ribbons or polymeric strands is less than 750 micrometers. Insome of these embodiments, the height of at least one of the polymericribbons or polymeric strands is in a range from 0.1 mm to less than 750micrometers (e.g., 0.3 mm to 0.745 mm or 0.5 mm to 0.745 mm).

FIG. 2 illustrates a perspective view of an embodiment of a polymericnetting 20 according to the present disclosure. In this perspectiveview, the length “1” of the polymeric ribbons and strands can beobserved.

Referring again to FIGS. 1 and 2, the polymeric ribbons 1, 11, 21, eachhave a first major surface 2, 12 that is intermittently joined to asingle polymeric strand 3, 13. That is, two or more polymeric strandsare not joined to the first major surface of the polymeric ribbon. Whenit is said that the first major surface of polymeric ribbon isintermittently joined to the single polymeric strand, it can be observedthat the polymeric strand oscillates between bonding to the polymericribbon and another portion of the netting on the opposite side of thepolymeric strand. In the embodiment illustrated in FIG. 2, two adjacentpolymeric ribbons 11, 21 are joined together by a single polymericstrand 13 at least partially alternately bonded to the two adjacentpolymeric ribbons 11, 21. However, this is not a requirement. Forexample, in some embodiments, the polymeric strand can oscillate betweenbonding to the polymeric ribbon and a non-oscillating strand that doesnot necessarily have a height-to-width aspect ratio of at least three toone. Since a major surface of the polymeric ribbon is intermittentlybonded to a polymeric strand, which is at least partially alternatelybonded to the polymeric ribbon and another strand or ribbon of thenetting, the polymeric ribbons are typically not intersected by thepolymeric strands. In any of the embodiments of the polymeric nettingdisclosed herein, the strands and ribbons of polymer typically do notsubstantially intersect each other (e.g., at least 50 (at least 55, 60,65, 70, 75, 80, 85, 90, 95, 99, or even 100) percent by number do notintersect each other) either by forming a superimposed intersectionpoint or an interlaid intersection point.

In FIG. 1, the heights h1 of the polymeric ribbons 1 are all about thesame size, and the heights h3 of the polymeric strands 3 are all thesame size, but as shown in FIGS. 2 to 4, this is not a requirement. Forexample, there may be two different types of polymeric ribbons 31, 41 asshown in FIG. 3. The height-to-width aspect ratio of polymeric ribbon 31is greater than the height-to-width aspect ratio of polymeric ribbon 41.In FIGS. 2 and 4, the polymeric ribbons 11, 21, 51 have a range ofheights. In FIG. 4, the height-to-width aspect ratio of the polymericribbons 51 is greater on the edges 55 of the polymeric netting 50 thanin the center 57. In these embodiments, at least some of the polymericribbons 51 have a height-to-width aspect ratio of at least three to one.

While in FIGS. 1 to 4, the spacings between the various polymericribbons and polymeric strands in the polymeric netting are approximatelyequal, this is not a requirement. The spacing between any two adjacentpolymeric ribbons 1, 11, 21, 31, 41, 51 or any two adjacent polymericstrands 3, 13, 33, 53 can vary in the cross-web direction. For example,any two adjacent polymeric ribbons or any two adjacent polymeric strandsmay be positioned more closely together at the center of the nettingthan on the edges or vice versa.

In the embodiments illustrated in FIGS. 1 to 4, the polymeric ribbonsand polymeric strands alternate. In some embodiments of the polymericnetting according to the present disclosure and/or made according to themethod disclosed herein, the polymeric ribbons and polymeric strandsalternate in at least a portion of the netting. In these embodiments andeven in other embodiments in which the polymeric ribbons and polymericstrands do not alternate, typically each major surface of the polymericribbon is intermittently bonded to only one polymeric strand.Furthermore, it should be noted that the spacing shown in thecross-sectional view of a plane of the polymeric netting shown in FIGS.3, 4, 5, 6, and 8 (described below) is idealized. In a typicallycross-sectional planar view, not all of the polymeric strands wouldappear to be identically bonded to the major surfaces of the polymericribbons. Instead, the positions of the strands may appear to be morelike that shown in the cross-sectional planar view of FIG. 7 and in theside view shown in FIG. 1.

Some embodiments of configurations of the polymeric netting according tothe present disclosure are illustrated in FIGS. 1, 5, and 6. In FIG. 1,the polymeric ribbons 1 each have a center line 4 bisecting majorsurface 2 and first and second edges 6, 8 symmetrically disposed onopposite sides of the center line 4. For each of the polymeric ribbons1, the associated single polymeric strand 3 is bonded to the majorsurface 2 at a location between the center line 4 and the first edges 6.In the illustrated embodiment, the single polymeric strand 3 is bondedto the two adjacent polymeric ribbons 1 at a location between the centerline 4 and the first edges 6. In other words, the single polymericstrand 3 is bonded to major surface 2 closer to the first edge 6 thanthe second edge 8. Explained yet another way, the polymeric netting 10has first and second opposing major surfaces 5, 7 transverse to themajor surfaces 2 of the polymeric ribbons 1. The second major surface 7of the polymeric netting 10 comprises the second edges 8 of thepolymeric ribbons 1, and the first major surface 5 of the polymericnetting 10 comprises the first edges 6 of the polymeric ribbons 1 andportions of at least some of the polymeric strands 3.

In the embodiment shown in FIG. 5, the polymeric ribbons 61 andpolymeric strands 63 are vertically aligned. In these embodiments, thesingle polymeric strand 63 is bonded to major surface 62 at a locationincluding center line 64. Explained yet another way, the polymericnetting 60 has first and second opposing major surfaces 65, 67transverse to the major surfaces 62 of the polymeric ribbons 61. Thefirst major surface 65 of the polymeric netting 60 comprises the firstedges 66 of the polymeric ribbons 61, and the second major surface 67 ofthe polymeric netting 60 comprises the second edges 68 of the polymericribbons 61. Neither the first nor second major surfaces 65, 67 comprisea portion of the polymeric strands 63.

In the embodiment shown in FIG. 6, the polymeric ribbons 71, 81 eachhave a center line 74, 84 bisecting major surface 72, 82, and second,top 78, 88 and first, bottom edges 76, 86 symmetrically disposed onopposite sides of the center line 74, 84, wherein some polymeric ribbons81 are bonded to their single polymeric strand 73 at a location betweenthe center line 84 and the second, top edge 88 and some of the polymericribbons 71 are bonded to their single polymeric strand 73 at a locationbetween the center line 74 at the first, bottom edge 76. In other words,the single polymeric strands 73 are bonded to a major surface 72 of afirst portion of polymeric ribbons 71 closer to the first edge 76 thanthe second edge 78, and the single polymeric strands 73 are bonded tomajor surface 82 of a second portion of polymeric ribbons 81 closer tothe second edge 88 than the first edge 86. Explained another way, thepolymeric netting 70 has first and second opposing major surfaces 75, 77transverse to the major surfaces 72, 82 of the polymeric ribbons 71, 81.The first major surface 75 of the polymeric netting 70 comprises thefirst edges 86 of a first group of the polymeric ribbons 81, and thesecond major surface 77 of the polymeric netting 70 comprises the secondedges 78 of a second group of the polymeric ribbons 71. Neither thefirst nor second major surfaces 75, 77 comprise a portion of thepolymeric strands 73. The first group of the polymeric ribbons 81 doesnot extend to the second major surface 77, and the second group of thepolymeric ribbons 71 does not extend to the first major surface 75.Further details about this embodiment can be found in co-pending U.S.Pat. App. Ser. No. 61/946,592 (Legatt et al.), filed Feb. 28, 2014, andincorporated by reference herein in its entirety.

While in FIGS. 1 to 6, the widths w1 of the polymeric ribbons are eachabout the same, and the widths w3 of the polymeric strands are all aboutthe same, this is also not a requirement. The widths of the polymericribbons and/or polymeric strands may change across the netting (e.g., ina direction transverse to the length of the polymeric ribbons andpolymeric strands). For example, at least one of the polymeric ribbonsor polymeric strands may have a larger width w1 or w3 at the center ofthe netting than on the edges or vice versa.

In the embodiments illustrated in FIGS. 1 to 6, the width w1 of thepolymeric ribbons is uniform from the second edge 8, 78, 88 to the firstedge 6, 76, 86. Again, this is not a requirement. For example, apolymeric netting 80 having ribbons with non-uniform widths between thetop and bottom edges is shown in FIG. 7. This embodiment is like theembodiment shown in FIG. 5 in which the polymeric ribbons 61 a andpolymeric strands 63 a are vertically centered. In polymeric netting 80,however, the width of the polymeric ribbon 61 a is wider at a locationincluding a center line 64 a than it is at the top and bottom edges 68and 66. That is, in the illustrated embodiment, the polymeric ribbon 61a is wider at the location where it is bonded to the polymeric strand 63a.

In the polymeric netting 80 illustrated in FIG. 7, the polymeric ribbon61 a is designed to have a greater width near the center line 64 a thanat the top and bottom edges 68 and 66. The width of the polymeric ribboncan also be designed to change from the top edge to bottom edge in otherways. For example, the width can be greater at the top edge 68 and/orbottom edge 66 than near the center line 64 a. The polymeric strands maybe bonded to the polymeric ribbons at these locations. The polymericribbons may also have random fluctuations in width caused by theextrusion process. In any situation in which the width of the polymericribbon is non-uniform, the width w1 of the polymeric ribbon for thepurposes of determining the height-to-width aspect ratio is measured atits smallest width.

Similarly, the height of the polymeric ribbon may be measured at itstallest height. The heights of the polymeric ribbons are generallyuniform. The polymeric ribbons in any of the embodiments of polymericnettings disclosed herein typically would not have any discrete posts(e.g., mechanical fasteners or hooks) upstanding from the edges of thepolymeric ribbons. Similarly, the polymeric nettings disclosed herein inany of their embodiments typically would not have any discrete posts(e.g., mechanical fasteners or hooks) on their first or second majorsurfaces.

In some embodiments in which the polymeric ribbons each have a centerline bisecting the major surface and first and second edgessymmetrically disposed on opposite sides of the center line, the firstedges of the polymeric ribbons comprise a different composition than thesecond edges of the polymeric ribbons. An embodiment of such a polymericnetting is shown in FIG. 8. In FIG. 8, the polymeric netting 90 includespolymeric ribbons 91 and polymeric strands 93. The polymeric ribbons 91each have a first portion 91 a and a second portion 91 b. The first andsecond portions 91 a and 91 b are made from different polymericcompositions. Likewise, the polymeric strands 93 each have a firstportion 93 a and a second portion 93 b. In these embodiments, thepolymeric netting 90 has first and second opposing major surfaces 95, 97transverse to the major surfaces 92 of the polymeric ribbons 91. Thefirst major surface 95 of the polymeric netting 90 comprises the firstedges 96 of polymeric ribbons 91 and second portions 93 b of polymericstrands 93, and the second major surface 97 of the polymeric netting 90comprises the second edges 98 of polymeric ribbons 91. The firstportions 91 a of the polymeric ribbons 91 and consequently the secondedges 98 comprise a first polymeric composition, and the second portions91 b of the polymeric ribbons 91 and consequently the first edges 96comprise a second polymeric composition. The first portions 93 a of thepolymeric strands comprise a third polymeric composition, and the secondportions 93 b of the polymeric strands 93 comprise a fourth polymericcomposition. In the illustrated embodiment, at least the first andsecond polymeric compositions are different, and the first polymericcomposition does not extend to the first edges 96 of the polymericribbons 91.

Although other methods may be useful, the polymeric nettings disclosedherein in any of their embodiments can conveniently be prepared by anextrusion die and/or method according to the present disclosure. Theextrusion die according to the present disclosure has a variety ofpassageways from cavities within the die to dispensing orifices. Thedispensing orifices each have a width, which is the dimension thatcorresponds to the width of a particular polymeric ribbon or polymericstrand, and a height, which is the dimension that corresponds to thethickness of the resulting extruded polymeric netting and the height ofa particular polymeric ribbon or polymeric strand.

In the extrusion die and method of making the polymeric nettingaccording to the present disclosure, the extrusion die has at least onecavity, a dispensing surface, and fluid passageways between the at leastone cavity and the dispensing surface. The dispensing surface has anarray of first dispensing orifices separated by an array of seconddispensing orifices. This means that for any two first dispensingorifices, there is at least one second dispensing orifice between them.However, it is possible that for any two first dispensing orifices,there is more than one second dispensing orifice between them, and theremay be dispensing orifices other than the second dispensing orificesbetween them in a side-by-side configuration.

The fluid passageways are capable of physically separating the polymersfrom the at least one cavity (e.g., first and second cavities andoptionally any further die cavities within the extrusion die) until thefluid passageways enter the dispensing orifices. The shape of thedifferent passageways within the die may be identical or different.Examples of passageway cross-sectional shapes include round, square, andrectangular shapes. These cross-sectional shapes, selection of polymericmaterial, and die swell can influence the cross-sectional shape of theribbons and strands.

In many embodiments, including the embodiments illustrated in FIGS. 9 to27A and 27B, the extrusion die includes at least a first and secondcavity, with first fluid passageways between the first cavity and thefirst dispensing orifices and second fluid passageways between thesecond cavity and the second dispensing orifices. The first and seconddispensing orifices each have a height and a width, the first dispensingorifices each have a height-to-width aspect ratio of at least 3:1 (insome embodiments, at least 5:1, 8:1, 10:1, 11:1, 15:1, 20:1, 30:1, or40:1), and the height of the first dispensing orifices is larger (insome embodiments, at least 2, 2.5, 3, 5, 10, or 20 times larger) thanthe height of the second dispensing orifices. In some embodiments,particularly embodiments of the extrusion die, the first dispensingorifices, second dispensing orifices, and any other dispensing orificesare arranged one-by-one across the dispensing surface. That is, in theseembodiments, in the width dimension of the die, the dispensing orificesare arranged singly or one-by-one regardless of the alignment of thedispensing orifices in these embodiments. For example, the dispensingorifices are not stacked in a group of two, three, or more in the heightdirection.

In some embodiments of the method according to the present disclosure,polymeric ribbons are dispensed from the first dispensing orifices at afirst speed while simultaneously polymeric strands are dispensed fromthe second dispensing orifices at a second speed, and the second speedis at least 2 times the first speed. In some embodiments, the secondspeed is in a range from 2 to 6 or from 2 to 4 times the first speed. Insome embodiments in which the extrusion die includes at least first andsecond cavities, the first cavity of the extrusion die is supplied witha first polymeric composition at a first pressure so as to dispense thepolymeric ribbons from the array of first dispensing orifices at a firstspeed, the second cavity of the extrusion die is supplied with a secondpolymeric composition at a second pressure so as to dispense thepolymeric strands from the array of second dispensing orifices at asecond speed, wherein the second speed is at least 2 (in someembodiments, 2 to 6, or 2 to 4) times the first speed. In otherembodiments of the method according to the present disclosure, polymericribbons are dispensed from the first dispensing orifices at a firstspeed while simultaneously polymeric strands are dispensed from thesecond dispensing orifices at a second speed, and the first speed is atleast 2 times the second speed. In some embodiments, the first speed isin a range from 2 to 6 or from 2 to 4 times the second speed. In someembodiments in which the extrusion die includes at least first andsecond cavities, the first cavity of the extrusion die is supplied witha first polymeric composition at a first pressure so as to dispense thepolymeric ribbons from the array of first dispensing orifices at a firstspeed, the second cavity of the extrusion die is supplied with a secondpolymeric composition at a second pressure so as to dispense thepolymeric strands from the array of second dispensing orifices at asecond speed, wherein the first speed is at least 2 (in someembodiments, 2 to 6, or 2 to 4) times the second speed.

While either the polymeric ribbons or polymeric strands may be made tooscillate, typically larger bond areas are observed when the polymericstrands are oscillating. Therefore, in the methods described below, thepolymeric strand is described as the oscillating strand.

The size of the polymeric ribbons and polymeric strands can be adjusted,for example, by the composition of the extruded polymers, velocity ofthe extruded strands, and/or the orifice design (e.g., cross sectionalarea (e.g., height and/or width of the orifices)). As taught in Int.Pat. App. Pub. No. WO 2013/028654 (Ausen et al.), a dispensing surfacewith a first polymer orifice three times greater in area than the secondpolymer orifice may not generate a net with polymeric ribbons with aheight greater than the polymeric stands depending on the identity ofthe polymeric compositions and the pressure within the cavities. In theembodiments of the extrusion die and method according to the presentdisclosure, the height-to-width aspect ratio of the orifices is at least5:1.

Conveniently, the extrusion die according to and/or useful forpracticing the present disclosure may be comprised of a plurality ofshims. The plurality of shims together define the at least one cavity,the dispensing surface, and the fluid passageways between the at leastone cavity and the dispensing surface. In some embodiments, theplurality of shims comprises a plurality of sequences of shims whereineach sequence comprises at least one first shim that provides a firstfluid passageway between the at least one cavity and at least one of thefirst dispensing orifices, and at least one second shim that provides asecond fluid passageway between the at least one cavity and at least oneof the second dispensing orifices. In some embodiments, the shimstogether define a first cavity and a second cavity, the extrusion diehaving a plurality of first dispensing orifices in fluid communicationwith the first cavity and having a plurality of second dispensingorifices in fluid communication with the second cavity. In someembodiments, the shims will be assembled according to a plan thatprovides a sequence of shims of diverse types. Since differentapplications may have different requirements, the sequences can havediverse numbers of shims. The sequence may be a repeating sequence thatis not limited to a particular number of repeats in a particular zone.Or the sequence may not regularly repeat, but different sequences ofshims may be used.

A plurality of shims that is useful for providing a polymeric nettingaccording to the present disclosure is shown in FIGS. 9 to 11, 12A, and12B. Referring now to FIG. 9, a plan view of shim 100 is illustrated.Shim 100 is useful in a sequence of shims 1000 shown in FIGS. 12A and12B. Other shims useful in this sequence are shown in FIGS. 10 and 11.Shim 100 has first aperture 110 a, second aperture 110 b, and thirdaperture 110 c. When shim sequence 1000 is assembled, first apertures110 a, 210 a, and 310 a in shims 100, 200, and 300 together define atleast a portion of first cavity 1012 a. Similarly, second apertures 110b, 210 b, and 310 b in shims 100, 200, and 300 together define at leasta portion of second cavity 1012 b, and third apertures 110 c, 210 c, and310 c in shims 100, 200, and 300 together define at least a portion ofthird cavity 1012 c. Shim 100 has several holes 147 to allow the passageof, for example, bolts to hold shim 100 and others to be described belowinto an assembly. Shim 100 has dispensing surface 167, and in thisparticular embodiment, dispensing surface 167 has indexing groove 180,which is useful for conveniently aligning the shims with anappropriately shaped key during assembly of the shims into a die, andidentification notch 182 to help verify that the die has been assembledin the desired manner. Shim 100 has shoulders 190 and 192, which can beconveniently engaged by compression blocks 2204 described below inconnection with FIGS. 22 and 23. Shim 100 has dispensing opening 156 butno integral connection between dispensing opening 156 and any ofapertures 110 a, 110 b, or 110 c. There is no connection, for example,from first aperture 110 a to dispensing opening 156, via, for example,passageway 168 a, but the flow has a route 1068 a to the dispensingsurface when shim 100 is assembled with shims 200 and 300 as illustratedin assembly drawing 1000 (see FIG. 12A). The dimensions of duct 154, andespecially dispensing opening 156 at its end, can be designed to providethe dimensions desired in the polymer strands extruded from them. Thedimensions of dispensing opening 156 and the dimensions of passageway158 a also influence the desired strand speed.

Referring now to FIG. 10, a plan view of shim 200 is illustrated. Shim200 has first aperture 210 a, second aperture 210 b, and third aperture210 c. When shim 200 is assembled with others as shown in FIG. 12A,aperture 210 a helps define first cavity 1012 a, aperture 210 b helpsdefine second cavity 1012 b, and aperture 210 c helps define thirdcavity 1012 c. Shim 200 has several holes 247 to allow the passage of,for example, bolts to hold shim 200 and others to be described belowinto an assembly. Shim 200 has dispensing surface 267, and in thisparticular embodiment, dispensing surface 267 has indexing groove 280and identification notch 282. Shim 200 also has shoulders 290 and 292.There is no passage from any of the cavities to dispensing surface 267since this shim creates a non-dispensing area along the width of thedie. In use, shim(s) 200 separates shims 100 producing polymeric strands3 from shims 300 producing polymeric ribbons 1.

Referring now to FIG. 11, a plan view of shim 300 is illustrated. Shim300 has first aperture 310 a, second aperture 310 b, and third aperture310 c. When shim 300 is assembled with others as shown in FIG. 12A,aperture 310 a helps define first cavity 1012 a, aperture 310 b helpsdefine second cavity 1012 b, and aperture 310 c helps define thirdcavity 1012 c. Shim 300 has several holes 347 to allow the passage of,for example, bolts to hold shim 300 and others to be described belowinto an assembly. Shim 300 has dispensing surface 367, and in thisparticular embodiment, dispensing surface 367 has indexing groove 380.Shim 300 also has shoulders 390 and 392. Shim 300 has dispensing opening356 but no integral connection between dispensing opening 356 and any ofand any of apertures 310 a, 310 b, or 310 c. There is no connection, forexample, from aperture 310 c to dispensing opening 356, via, forexample, passageway 368 c, but the flow has a route 1068 c to thedispensing surface when shim 300 is assembled with shims 100 and 200 asillustrated in sequence 1000 (see FIG. 12A). Comparing FIG. 11 with FIG.9, one observes that dispensing opening 356 is bigger than dispensingopening 156. In some embodiments, dispensing opening 356 is at leasttwice the size of dispensing opening 156. In some embodiments,dispensing opening 356 is at least 2.5, 3, 5, 10, or 20 times biggerthan dispensing opening 156.

FIGS. 12A and 12B illustrate a perspective assembly drawing of asequence of shims, collectively 1000, employing the shims of FIGS. 9 to11 so as to produce a polymeric netting 10 as shown in FIG. 1.Proceeding left to right, sequence 1000 includes two shims 100 that canextrude polymeric strands 3, two shims 200, two shims 300 that canextrude polymeric ribbons 1, and two shims 200. The first dispensingorifices 1001 each have an aspect ratio defined by height h1001 andwidth w1001. The height-to-width aspect ratio is at least three to one(in some embodiments, at least 5:1, 8:1, 10:1, 11:1, 15:1, 20:1, 30:1,or 40:1). First dispensing orifices 1001 and second dispensing orifices1003 are separated by two instances of shims 200. The separation causesthe separation of polymeric ribbons 1 from polymeric strands 3 in thepolymeric netting 10. The height h1001 of the first dispensing orificesis greater than the height h1003 of the second dispensing orifices. Insome embodiments, the height of the first dispensing orifices h1001 isat least 2, 2.5, 3, 5, 10, or 20 times larger than the height of thesecond dispensing orifices h1003.

Modifications of the sequence 1000 shown in FIGS. 12A and 12B can beused in combination with sequence 1000, for example, to make thepolymeric nettings 20, 40, and 50, as shown in FIGS. 2, 3, and 4. Tomake polymeric netting 40 shown in FIG. 3, sequence 1000 can bealternated with another sequence similar to 1000 in which shim 300 has asomewhat smaller opening 356, for example. While shim 300 can be usefulfor extruding polymeric ribbons 31, a shim with a somewhat smalleropening 356 can be useful for extruding polymeric ribbons 41. In someembodiments, sequence 1000 can be alternated with another sequencesimilar to 1000 in which shim 300 is replaced by shim 100, and the flowrate of the polymer coming from cavity 1012 c can be adjusted so thatthis strand does not oscillate. This sequence can make a polymericnetting in which a polymeric strand 33 oscillates between bonding to thepolymeric ribbon 31 and bonding to a non-oscillating strand that doesnot necessarily have a height-to-width aspect ratio of at least three toone. To make polymeric netting 20 shown in FIG. 2, sequence 1000 can becombined with similar sequences in which shim 300 is modified to haveprogressively smaller openings 356, for example, to provide a pluralityof shim sequences. While shim 300 can be useful for extruding polymericribbons 11, a shim with a somewhat smaller opening 356 can be useful forextruding polymeric ribbons 21. Such a plurality of shim sequences canbe repeated in the opposite order to provide a polymeric netting 50 asshown in FIG. 4.

In a method using the extrusion die shown in FIGS. 12A and 12B to make apolymeric netting as shown in FIG. 1, for example, polymer from firstcavity 1012 a emerges as polymeric strands 3 from second dispensingorifices 1003, and polymer from third cavity 1012 c emerges as polymericribbons 1 from first dispensing orifices 1001. The dimensions of thefluid passageways and the pressures in cavities 1012 a and 1012 c aretypically selected so that the speed of oscillating polymeric strands 3is between about 2 and 6 (in some embodiments, 2 and 4) times greaterthan the speed of polymeric ribbons 1. To make a polymeric netting asshown in FIG. 1, second cavity 1012 b is unused, but this cavity couldbe used to introduce another polymeric composition in polymeric netting10.

A polymeric netting such as that indicated by polymeric netting 60 inFIG. 5 can be made, for example, using a shim sequence shown in FIGS.15A and 15B. FIGS. 15A and 15B show a perspective assembly of a sequenceof shims including shims 200 as described above in connection with FIG.10 and shims 400 and 500, described below in connection with FIGS. 13and 14, respectively.

Referring now to FIG. 13, a plan view of shim 400 is illustrated. Shim400 has first aperture 410 a, second aperture 410 b, and third aperture410 c. When shim 400 is assembled with others as shown in FIG. 15,aperture 410 a helps define first cavity 1112 a, aperture 410 b helpsdefine second cavity 1112 b, and aperture 410 c helps define thirdcavity 1112 c. Shim 400 has several holes 447 to allow the passage of,for example, bolts to hold shim 400 and others to be described belowinto an assembly. Shim 400 has dispensing surface 467, and in thisparticular embodiment, dispensing surface 467 has indexing groove 480and identification notch 482. Shim 400 also has shoulders 490 and 492.Shim 400 has dispensing opening 456 but no integral connection betweendispensing opening 456 and any of apertures 410 a, 410 b, or 410 c.There is no connection, for example, from aperture 410 c to dispensingopening 456, via, for example, passageway 468 a, but the flow has aroute 1168 a to the dispensing surface in theperpendicular-to-the-plane-of-the-drawing dimension when shim 400 isassembled with shims 200 and 500 as illustrated in sequence 1100 (seeFIG. 15A). The dimensions of 456 can be designed to provide thedimensions desired in the polymer strands extruded therefrom. Thedimensions of dispensing opening 456 and the dimensions of passagewayleading to it also influence the strand speed.

Referring now to FIG. 14, a plan view of shim 500 is illustrated. Shim500 has first aperture 510 a, second aperture 510 b, and third aperture510 c. When shim 500 is assembled with others as shown in FIGS. 15A and15B, aperture 510 a helps define first cavity 1112 a, aperture 510 bhelps define second cavity 1112 b, and aperture 510 c helps define thirdcavity 1112 c. Shim 500 has several holes 547 to allow the passage of,for example, bolts to hold shim 500 and others to be described belowinto an assembly. Shim 500 has dispensing surface 567, and in thisparticular embodiment, dispensing surface 567 has indexing groove 580.Shim 500 also has shoulders 590 and 592. Shim 500 has dispensing opening556 but has no integral connection between dispensing opening 556 andany of apertures 510 a, 510 b, or 510 c. There is no connection, forexample, from aperture 510 b to dispensing opening 556, via, forexample, passageway 568 b, but the flow has a route 1168 b to thedispensing surface when shim 500 is assembled with shims 200 and 400 asillustrated in assembly drawing (see FIG. 15A).

FIGS. 15A and 15B illustrate a perspective assembly drawing of asequence of shims, collectively 1100, employing the shims of FIGS. 10,13, and 14 so as to produce a polymeric netting 60 as shown in FIG. 5.Proceeding left to right, sequence 1100 includes four shims 400 that canextrude polymeric strands 63, four shims 200, two shims 500 that canextrude polymeric ribbons 61, and four shims 200. Dispensing orifices1101 and 1103 are separated by four instances of shims 200. Theseparation causes the separation of polymeric ribbons 61 from polymericstrands 63 in the polymeric netting 60. The sequence of shims 1100 issimilar to that of 1000 except that the dispensing orifices 1101 and1103 are vertically aligned so that the second dispensing orifices arelocated in the cross-sectional middle of the dispensing surface 1167. Asin the embodiment shown in FIG. 12B, the first dispensing orifices 1101each have an aspect ratio defined by height h1101 and width w1101 of atleast three to one (in some embodiments, at least 5:1, 8:1, 10:1, 11:1,15:1, 20:1, 30:1, or 40:1), and the height h1101 of the first dispensingorifices is at least 2, 2.5, 3, 5, 10, or 20 times larger than theheight h1103 of the second dispensing orifices.

In a method using the extrusion die shown in FIGS. 15A and 15B to make apolymeric netting as shown in FIG. 5, for example, polymer from firstcavity 1112 a emerges as polymeric strands 63 from second dispensingorifices 1103, and polymer from second cavity 1112 b emerges aspolymeric ribbons 61 from first dispensing orifices 1101. The dimensionsof the fluid passageways and the pressures in cavities 1112 a and 1112 bare typically selected so that the speed of oscillating polymericstrands 63 is between about 2 and 6 (in some embodiments, 2 and 4) timesgreater than the speed of polymeric ribbons 61. To make a polymericnetting as shown in FIG. 5, third cavity 1112 c is unused, but thiscavity could be used to introduce another polymeric composition inpolymeric netting 60.

A polymeric netting such as that indicated by polymeric netting 70 inFIG. 6 can be made, for example, using a shim sequence shown in FIGS.18A and 18B. FIGS. 18A and 18B show a perspective assembly of a sequenceof shims including shims 200 and 300 as described above in connectionwith FIGS. 10 and 11, respectively, and shims 600 and 700, describedbelow.

Referring now to FIG. 16, a plan view of shim 600 is illustrated. Shim600 has first aperture 610 a, second aperture 610 b, and third aperture610 c. When shim 600 is assembled with others as shown in FIG. 18A,aperture 610 a helps define first cavity 1212 a, aperture 610 b helpsdefine second cavity 1212 b, and aperture 610 c helps define thirdcavity 1212 c. Shim 600 has several holes 647 to allow the passage of,for example, bolts to hold shim 600 and others to be described belowinto an assembly. Shim 600 has dispensing surface 667, and in thisparticular embodiment, dispensing surface 667 has indexing groove 680and identification notch 682. Shim 600 also has shoulders 690 and 692.Shim 600 has dispensing opening 656 but has no integral connectionbetween dispensing opening 656 and any of apertures 610 a, 610 b, or 610c. There is no connection, for example, from aperture 610 b todispensing opening 656, via, for example, passageway 668 b, but the flowhas a route 1268 b to the dispensing surface when shim 600 is assembledwith shims 200, 300, and 700 as illustrated in sequence 1200 (see FIG.18A). The dimensions of 656 can be designed to provide the dimensionsdesired in the polymer strands extruded therefrom. The dimensions ofdispensing opening 656 and the dimensions of passageway leading to italso influence the strand speed. Referring now to FIG. 17, a plan viewof shim 700 is illustrated. Shim 700 is similar to shim 300, shown inFIG. 11. Shim 700 has first aperture 710 a, second aperture 710 b, andthird aperture 710 c. When shim 700 is assembled with others as shown inFIGS. 18A and 18B, aperture 710 a helps define first cavity 1212 a,aperture 710 b helps define second cavity 1212 b, and aperture 710 chelps define third cavity 1212 c. Shim 700 has several holes 747 toallow the passage of, for example, bolts to hold shim 700 and others tobe described below into an assembly. Shim 700 has dispensing surface767, and in this particular embodiment, dispensing surface 767 hasindexing groove 780. Shim 700 also has shoulders 790 and 792. Shim 700has dispensing opening 756 but has no integral connection betweendispensing opening 756 and any of apertures 710 a, 710 b, or 710 c.There is no connection, for example, from aperture 710 a to dispensingopening 756, via, for example, passageway 768 a, but the flow has aroute 1268 a to the dispensing surface when shim 700 is assembled withshims 200, 300, and 600 as illustrated in assembly drawing (see FIG.18A). As in FIG. 11, dispensing opening 756 is bigger than dispensingopening 656. In some embodiments, dispensing opening 756 is at leasttwice the size of dispensing opening 656. In some embodiments,dispensing opening 756 is at least 2.5, 3, 5, 10, or 20 times biggerthan dispensing opening 656.

FIGS. 18A and 18B illustrate a perspective assembly drawing of asequence of shims, collectively 1200, employing the shims of FIGS. 10,11, 16, and 17 so as to produce a polymeric netting 70 as shown in FIG.6. Proceeding left to right, the sequence 1200 comprises two shims 700that can extrude polymeric ribbons 81, two shims 200, two shims 600 thatcan extrude polymeric strands 73, two shims 200, two shims 300 that canextrude polymeric ribbons 71, two shims 200, two shims 600 that canextrude polymeric strands 73, and two shims 200. The first dispensingorifices 1201 each have a height-to-width aspect ratio of at least threeto one (in some embodiments, at least 5:1, 8:1, 10:1, 11:1, 15:1, 20:1,30:1, or 40:1). Dispensing orifices 1201 and 1203 are separated by shims200, which causes the separation of polymeric ribbons 71 and 81 frompolymeric strands 73 in the polymeric netting 70. As in the embodimentshown in FIG. 12B, the height h1201 of the first dispensing orifices isat least 2, 2.5, 3, 5, 10, or 20 times larger than the height h1203 ofthe second dispensing orifices. In the method disclosed herein polymerfrom first cavity 1212 a emerges as polymeric ribbons 81 from firstdispensing orifices 1201, polymer from second cavity 1212 b emerges asoscillating strands 73 from second dispensing orifices 1203, and polymerfrom third cavity 1212 c emerges as polymeric ribbons 71 from firstdispensing orifices 1201. The dimensions of the fluid passageways andthe pressures in the cavities are typically selected so that the speedof oscillating polymeric strands 73 is between about 2 and 6 (in someembodiments, 2 and 4) times greater than the speed of polymeric ribbons71 and 81.

In the embodiment illustrated in FIGS. 18A and 18B, the seconddispensing orifices 1203 are positioned closer to the top edges than thebottom edges of some of the first dispensing orifices 1201, and thesecond dispensing orifices 1203 are positioned closer to the bottomedges than the top edges of some of the first dispensing orifices 1201.In other embodiments, it is possible to make the top edges of some ofthe first dispensing orifices substantially aligned with the top edgesof the second dispensing orifices and the bottom edges of some of thefirst dispensing openings substantially aligned with the bottom edges ofthe second dispensing orifices. However, it can be useful to have thesecond dispensing openings positioned somewhat above the bottom andbelow the top of the first dispensing openings, because the oscillatingstrand typically has more die swell, and a larger bond area can beachieved.

A polymeric netting such as that indicated by polymeric netting 80 inFIG. 7 can be made, for example, using a shim sequence shown in FIGS.21A and 21B. FIGS. 21A and 21B show a perspective assembly of a sequenceof shims including shims 200 and 500 as described above in connectionwith FIGS. 10 and 14, respectively, and shims 800 and 900, describedbelow.

Referring now to FIG. 19, a plan view of shim 800 is illustrated. Shim800 has first aperture 810 a, second aperture 810 b, and third aperture810 c. When shim 800 is assembled with others as shown in FIGS. 21A and21B, aperture 810 a helps define first cavity 1312 a, aperture 810 bhelps define second cavity 1312 b, and aperture 810 c helps define thirdcavity 1312 c. Shim 800 has several holes 847 to allow the passage of,for example, bolts to hold shim 800 and others to be described belowinto an assembly. Shim 800 has dispensing surface 867, and in thisparticular embodiment, dispensing surface 867 has indexing groove 880and identification notch 882. Shim 800 also has shoulders 890 and 892.Shim 800 has dispensing opening 856 but has no integral connectionbetween dispensing opening 856 and any of apertures 810 a, 810 b, or 810c. There is no connection, for example, from aperture 810 a todispensing opening 856, via, for example, passageway 868 a, but the flowhas a route 1368 a to the dispensing surface when shim 800 is assembledwith shims 200, 500, and 900 as illustrated in sequence 1300 (see FIG.21A).

Referring now to FIG. 20, a plan view of shim 900 is illustrated. Shim900 has first aperture 910 a, second aperture 910 b, and third aperture910 c. When shim 900 is assembled with others as shown in FIGS. 21A and21B, aperture 910 a helps define first cavity 1312 a, aperture 910 bhelps define second cavity 1312 b, and aperture 910 c helps define thirdcavity 1312 c. Shim 900 has several holes 947 to allow the passage of,for example, bolts to hold shim 900 and others to be described belowinto an assembly. Shim 900 has dispensing surface 967, and in thisparticular embodiment, dispensing surface 967 has indexing groove 980and identification notch 982. Shim 900 also has shoulders 990 and 992.Shim 900 has dispensing opening 956 but no integral connection betweendispensing opening 956 and any of apertures 910 a, 910 b, or 910 c.There is no connection, for example, from aperture 910 b to dispensingopening 956, via, for example, passageway 968 b, but the flow has aroute 1368 b to the dispensing surface when shim 900 is assembled withshims 200, 500, and 800 as illustrated in assembly drawing (see FIG.21A). The dimensions of 956 can be designed to provide the dimensionsdesired in the polymer strands extruded therefrom. FIGS. 21A and 21Billustrate a perspective assembly drawing of a sequence of shims,collectively 1300, employing the shims of FIGS. 10, 14, 19, and 20 so asto produce a polymeric netting 80 as shown in FIG. 7. Proceeding left toright, the sequence 1300 comprises three shims 800 that can extrudepolymeric strands 63 a, three shims 200, one shim 900 that can extrude aportion of the polymeric ribbons 61 a around center line 64 a, two shims500 that can extrude polymeric ribbons 61 a, one more shim 900 that canextrude a portion of the polymeric ribbons 61 a around center line 64 a,and three shims 200. Shim 900 and shim 500 both extrude polymer fromcavity 1312 b although the dispensing opening 956 is much smaller thandispensing opening 556. Openings 956 and 556 are vertically centered sothat more polymer is extruded from cavity 1312 b to the central portionof polymeric ribbon 61 a. Dispensing orifices 1301 and 1303 areseparated by shims 200, which causes the separation of polymeric ribbons61 a from polymeric strands 63 a in the polymeric netting 80. The firstdispensing orifices 1301 each have a height h1301 to width w1301 aspectratio of at least three to one (in some embodiments, at least 5:1, 8:1,10:1, 11:1, 15:1, 20:1, 30:1, or 40:1), when width w1301 is measured atits narrowest point. As in the embodiment shown in FIG. 12B, the heighth1301 of the first dispensing orifices is larger (in some embodiments,at least 2, 2.5, 3, 5, 10, or 20 times larger) than the height h1303 ofthe second dispensing orifices.

In a method using the extrusion die shown in FIGS. 21A and 21B to make apolymeric netting as shown in FIG. 7, for example, polymer from firstcavity 1312 a emerges as polymeric strands 63 a from second dispensingorifices 1303, and polymer from second cavity 1312 b emerges aspolymeric ribbons 61 a from first dispensing orifices 1301. Thedimensions of the fluid passageways and the pressures in cavities 1312 aand 1312 b are typically selected so that the speed of oscillatingpolymeric strands 63 a is between about 2 and 6 (in some embodiments, 2and 4) times greater than the speed of polymeric ribbons 61 a. To make apolymeric netting as shown in FIG. 7, third cavity 1312 c is unused, butthis cavity could be used to introduce another polymeric composition inpolymeric netting 80.

A modification of the shim sequence shown in FIGS. 21A and 21B may beuseful for providing polymeric nettings that are similar to those shownin FIG. 7 but have polymeric ribbons in which more polymer is extrudedfrom cavity 1312 b to at least one of the bottom edges 66 or top edges68 instead of at the central portion 64 a.

An exploded perspective view of an embodiment of a mount suitable for anextrusion die composed of multiple repeats of the sequence of shims isillustrated in FIGS. 22 and 23. In some embodiments of extrusion diesdescribed herein, there will be a large number of very thin shims(typically several thousand shims; in some embodiments, at least 1000,2000, 3000, 4000, 5000, 6000, 7000, 8000, 9000, or even at least10,000), of diverse types (e.g., shims 100, 200, and 300), compressedbetween two end blocks (e.g., 2244 a and 2244 b). Conveniently, throughbolts can be used to assemble the shims to the end blocks 2244 a and2244 b, passing through holes 547 in the shims. Inlet fittings 2250 a,2250 b, and 2250 c are provided on end blocks 2244 a and 2244 brespectively to introduce the materials to be extruded into extrusiondie 2000. In some embodiments, inlet fittings 2250 a, 2250 b, and 2250 care connected to melt trains of conventional type. In some embodiments,cartridge heaters 2052 are inserted into receptacles extrusion die 2000to maintain the materials to be extruded at a desirable temperaturewhile in the die. The ordinary artisan may perceive alternatives forassembling the extrusion die other than that shown in the illustratedembodiment. In some embodiments, the assembled shims (convenientlybolted between the end blocks) further comprise a manifold body (notshown) for supporting the shims. The manifold body has at least one (ormore (e.g., two or three, four, or more)) manifold therein, the manifoldhaving an outlet. An expansion seal (e.g., made of copper or alloysthereof) is disposed so as to seal the manifold body and the shims, suchthat the expansion seal defines a portion of at least one of thecavities (in some embodiments, a portion of all the cavities), and suchthat the expansion seal allows a conduit between the manifold and thecavity.

Compression blocks 2204 have a notch 2206 that conveniently engages theshoulders on the shims (e.g., 590 and 592 on 500). When mount 2000 iscompletely assembled, compression blocks 2204 are attached by, forexample, machine bolts to backplates 2208. Referring now to FIG. 23, aperspective view of mount 2000 of FIG. 22 is illustrated in a partiallyassembled state. A few shims (e.g., 500) are in their assembledpositions to show how they fit within mount 2000, but most of the shimsthat would make up an assembled die have been omitted for visualclarity.

In any of the shims and sequences described above, the shims can havethicknesses in the range from 50 micrometers to 500 micrometers,although thicknesses outside of this range may also be useful. For widerfluid passageways and dispending orifices, several smaller thicknessshims may be stacked together, or single shims of the desired passagewaywidth may be used. The shims are typically metal, for example, stainlesssteel. To reduce size changes with heat cycling, metal shims aretypically heat-treated. The shims can be made by conventionaltechniques, including wire electrical discharge and laser machining.Often, a plurality of shims are made at the same time by stacking aplurality of sheets and then creating the desired openingssimultaneously. Variability of the flow channels is preferably within0.025 mm (1 mil), more preferably, within 0.013 mm (0.5 mil). The shimsare tightly compressed to prevent gaps between the shims and polymerleakage. For example, 12 mm (0.5 inch) diameter bolts are typically usedand tightened, at the extrusion temperature, to their recommended torquerating. Also, the shims are aligned to provide uniform extrusion out theextrusion orifice, as misalignment can lead to strands extruding at anangle out of the die which inhibits desired bonding of the net. Asdescribed above, to aid in alignment, an indexing groove can be cut intothe shims to receive an alignment key. Also, a vibrating table can beuseful to provide a smooth surface alignment of the extrusion tip.

Typically, the fluid passageways have heights in a range from 50micrometers to 3 mm, and lengths less than 5 mm (with generally apreference for smaller lengths for decreasingly smaller passagewaythicknesses), although heights and lengths outside of these ranges mayalso be useful. The height of the first dispensing orifices may be in arange from 50 micrometers to 3 millimeters (mm). In some embodiments,the height of the first dispensing orifices is greater than 750micrometers. In some of these embodiments, the height of the firstdispensing orifices is in a range from greater than 750 micrometers to 3mm (e.g., 0.775 mm to 3 mm or 0.8 mm to 2.6 mm). In some embodiments,the height of at least one of the first dispensing orifices or thesecond dispensing orifices is less than 750 micrometers. In some ofthese embodiments, the height of the first dispensing orifices andsecond dispensing orifices is in a range from 0.1 mm to less than 750micrometers (e.g., 0.3 mm to 0.745 mm or 0.5 mm to 0.745 mm).

In some embodiments of the dies useful for extruding a polymer, each ofthe first and the second dispensing orifices have a width, and each ofthe first and the second dispensing orifices are separated by at leastthe width of the respective dispensing orifice and up to 2 times thewidth of the respective dispensing orifice. When the dispensing orificeshave different widths, the separation between the first and secondorifices may be at least the width of the wider opening and up to 2times the width of the wider opening. The spacing between orificesshould be sufficient to maintain a distance between adjacent strands asthey exit the die. This spacing accommodates die swell at the dispensingtip. If the spacing between orifices is too great, the strands andribbons after extrusion at different speeds will not repeatedly collidewith each other and will not form the repeating bonds of the polymericnetting

In general, it has been observed that the rate of strand bonding isproportional to the extrusion speed of the polymeric strands or ribbonsthat are extruded at the faster speed. Further, it has been observedthat this bonding rate can be increased, for example, by increasing thepolymer flow rate for a given orifice size, or by decreasing the orificearea for a given polymer flow rate. It has also been observed that thedistance between bonds is inversely proportional to the rate of strandbonding, and proportional to the speed that the net is drawn away fromthe die. Thus, it is believed that the distance between bonds and thenet basis weight can be independently controlled by design of theorifice cross sectional area, the takeaway speed, and the extrusion rateof the polymer. For example, relatively high basis weight nettings, witha relatively short bond pitch can be made by extruding at a relativelyhigh polymer flow rate, with a relatively low netting takeaway speed,using a die with a relatively small second orifice area.

In some embodiments, it may be useful to have the number of polymericribbons present per centimeter of cross direction width vary across thewidth of the polymeric netting. One way of achieving this is to apply aspreading force to at least a portion of the polymeric netting, such asby running the web over a bowed roller, diverging rails, or divergingdisks. Once spread, attaching polymeric netting to another layer (e.g.,a carrier or a layer in an absorbent article as described below) can beuseful for maintaining the web in this spread open condition. Spreadingin the cross direction causes the openings in the polymeric netting tobecome larger in the cross direction with the original dimension of theindividual openings in the machine direction defined by the averagemachine direction spacing of contacts between the polymeric ribbons andthe polymeric strands. In some embodiments it may be desirable tostretch the polymeric netting in the machine direction or in both across direction and the machine direction to create larger openingand/or to reduce the weight and cost of the polymeric netting on a perunit area basis. Monoaxial stretching in the machine direction, which isthe lengthwise direction of the polymeric ribbons and polymeric strands,can be performed by propelling the web over rolls of increasing speed. Aversatile stretching method that allows for monoaxial, sequentialbiaxial, or simultaneous biaxial stretching of a thermoplastic webemploys a flat film tenter apparatus. Such an apparatus grasps the webusing a plurality of clips, grippers, or other edge-grasping means alongopposing edges of the thermoplastic web in such a way that monoaxial,sequential biaxial, or simultaneous biaxial stretching in the desireddirection is obtained by propelling the grasping means at varying speedsalong divergent rails. Increasing clip speed in the machine directiongenerally results in machine-direction stretching. Monoaxial and biaxialstretching can be accomplished, for example, by the methods andapparatus disclosed in U.S. Pat. No. 7,897,078 (Petersen et al.) and thereferences cited therein. Flat film tenter stretching apparatuses arecommercially available, for example, from Brückner Maschinenbau GmbH,Siegsdorf, Germany.

Although in the embodiments shown in FIGS. 9 to 21, the first and seconddispensing orifices are collinear, this is not a requirement. In someembodiments, the first dispensing orifices are collinear with eachother, and the second dispensing orifices are collinear with each other,but the first and second dispensing orifices do not overlap. When thefirst and second dispensing orifices do not overlap with each other, itmay be desirable to extrude the strands horizontally.

While the embodiments of the extrusion die and method described above inconnection with FIGS. 9 to 21 supply polymeric ribbons and polymericstrands of a polymer netting from separate cavities, other embodimentsinclude providing an extrusion die comprising a plurality of shimspositioned adjacent to one another, the shims together defining acavity, the extrusion die having a plurality of first dispensingorifices in fluid communication with the cavity and a plurality ofsecond dispensing orifices in fluid communication with the cavity, suchthat the first and second dispensing orifices are alternated. In theseembodiments, polymeric ribbons are dispensed from the first dispensingorifices at a first speed while simultaneously polymeric strands aredispensed from the second dispensing orifices at a second speed, whereinthe second speed is at least 2 (in some embodiments, in a range from 2to 6 or 4 to 6) times the first speed. Since there is only one cavity,the polymeric ribbons and polymeric strands in the resulting netting aremade from the same composition. To prepare a polymeric netting from anextrusion die having only one cavity, a shim sequence such as that shownin FIGS. 44 to 48 in Int. Pat. Appl. Pub. No. WO 2013/028654 (Ausen etal.) may be useful, with the modification that the shims providing thefirst dispensing orifices providing the polymeric ribbons have an aspectratio of at least 3:1, 5:1, 7:1, or more and may lack a restriction setback from the dispensing orifice.

The polymeric compositions useful in the polymeric nettings and methodsdescribed above in any of their embodiments may be the same ordifferent. In some embodiments, the polymeric ribbons and polymericstrands comprise different polymeric compositions. These nets can beprepared, for example, by extrusion using any embodiments of the methoddescribed above by using different polymeric compositions in the firstand second cavities. The different polymeric compositions in thepolymeric ribbons and polymeric strands may be selected for theirsurface properties or their bulk properties (e.g., tensile strength,elasticity, microstructure, color, refractive index, etc). Furthermore,polymeric compositions can be selected to provide specific functional oraesthetic properties in the polymeric netting such ashydrophilicity/hydrophobicity, elasticity, softness, hardness,stiffness, bendability, or colors. The term “different” in terms ofpolymeric compositions can also refer to at least one of (a) adifference of at least 2% in at least one infrared peak, (b) adifference of at least 2% in at least one nuclear magnetic resonancepeak, (c) a difference of at least 2% in the number average molecularweight, or (d) a difference of at least 5% in polydispersity.

In any embodiments of the method disclosed herein, polymers used to makethe polymeric ribbons and polymeric strands are selected to becompatible with each other such that the polymeric ribbons and polymericstrands bond together at bond regions. Bonding generally refers tomelt-bonding, and the bonds between polymer strands and polymer ribbonscan be considered to be melt-bonded. The bonding occurs in a relativelyshort period of time (typically less than 1 second). The bond regions onthe major surface of the polymeric ribbons, as well as the polymericstrands, typically cool through air and natural convection and/orradiation. In selecting polymers for the polymeric ribbons and polymericstrands, in some embodiments, it may be desirable to select polymers ofbonding strands that have dipole interactions (or H-bonds) or covalentbonds. Bonding between strands has been observed to be improved byincreasing the time that the polymeric ribbons and polymeric strands aremolten to enable more interaction between polymers. Bonding of polymershas generally been observed to be improved by reducing the molecularweight of at least one polymer and or introducing an additionalco-monomer to improve polymer interaction and/or reduce the rate oramount of crystallization.

Examples of polymeric materials from which the polymeric netting can bemade include thermoplastic polymers. Suitable thermoplastic polymers forthe polymeric nettings include polyolefin homopolymers such aspolyethylene and polypropylene, copolymers of ethylene, propylene and/orbutylene; copolymers containing ethylene such as ethylene vinyl acetateand ethylene acrylic acid; ionomers based on sodium or zinc salts ofethylene methacrylic acid or ethylene acrylic acid; polyvinyl chloride;polyvinylidene chloride; polystyrenes and polystyrene copolymers(styrene-maleic anhydride copolymers, styrene acrylonitrile copolymers);nylons; polyesters such as poly(ethylene terephthalate), polyethylenebutyrate and polyethylene napthalate; polyamides such aspoly(hexamethylene adipamide); polyurethanes; polycarbonates; poly(vinylalcohol); ketones such as polyetheretherketone; polyphenylene sulfide;polyacrylates; cellulosics; fluoroplastics; polysulfones; siliconepolymers; and mixtures thereof. The die and method according to thepresent disclosure may also be useful for co-extruding polymericmaterials that can be crosslinked (e.g., by heat or radiation). When aheat curable resin is used, the die can be heated to start the cure soas to adjust the viscosity of the polymeric material and/or the pressurein the corresponding die cavity. In some embodiments, at least one ofthe polymeric ribbons or polymeric strands is made from a polyolefin(e.g., polyethylene, polypropylene, polybutylene, ethylene copolymers,propylene copolymers, butylene copolymers, and copolymers and blends ofthese materials).

In some embodiments, the polymeric ribbons are elastic, the polymericstrands are elastic, or both the polymeric ribbons and polymeric strandsare elastic. For example, the second polymeric composition may includethermoplastic elastomers such as ABA block copolymers, polyurethaneelastomers, polyolefin elastomers (e.g., metallocene polyolefinelastomers), polyamide elastomers, ethylene vinyl acetate elastomers,polyvinyl ethers, acrylics, especially those having long chain alkylgroups, poly-alpha-olefins, asphaltics, silicones, polyester elastomers,and natural rubber. An ABA block copolymer elastomer generally is onewhere the A blocks are polystyrenic, and the B blocks are conjugateddienes (e.g., lower alkylene dienes). The A block is generally formedpredominantly of substituted (e.g., alkylated) or unsubstituted styrenicmoieties (e.g., polystyrene, poly(alphamethylstyrene), orpoly(t-butylstyrene)), having an average molecular weight from about4,000 to 50,000 grams per mole. The B block(s) is generally formedpredominantly of conjugated dienes (e.g., isoprene, 1,3-butadiene, orethylene-butylene monomers), which may be substituted or unsubstituted,and has an average molecular weight from about 5,000 to 500,000 gramsper mole. The A and B blocks may be configured, for example, in linear,radial, or star configurations. An ABA block copolymer may containmultiple A and/or B blocks, which blocks may be made from the same ordifferent monomers. A typical block copolymer is a linear ABA blockcopolymer, where the A blocks may be the same or different, or a blockcopolymer having more than three blocks, predominantly terminating withA blocks. Multi-block copolymers may contain, for example, a certainproportion of AB diblock copolymer, which tends to form a more tackyelastomeric film segment. Other elastic polymers can be blended withblock copolymer elastomers, and various elastic polymers may be blendedto have varying degrees of elastic properties.

Many types of thermoplastic elastomers are commercially available,including those from BASF, Florham Park, N.J., under the tradedesignation “STYROFLEX”, from Kraton Polymers, Houston, Tex., under thetrade designation “KRATON”, from Dow Chemical, Midland, Mich., under thetrade designation “PELLETHANE”, “ENGAGE”, “INFUSE”, VERSIFY”, or“NORDEL”, from DSM, Heerlen, Netherlands, under the trade designation“ARNITEL”, from E. I. duPont de Nemours and Company, Wilmington, Del.,under the trade designation “HYTREL”, from ExxonMobil, Irving, Tex.under the trade designation “VISTAMAXX”, and more.

Mixtures of any of the above-mentioned polymers may be useful in thepolymeric nettings disclosed herein. For example, a polyolefin may beblended with an elastomeric polymer to lower the modulus of thepolymeric composition, which may be desirable for certain application.Such a blend may or may not be elastic.

In some embodiments, polymeric materials from which polymeric nettingcan be made comprise a colorant (e.g., pigment and/or dye) forfunctional (e.g., optical effects) and/or aesthetic purposes (e.g., eachhas different color/shade). Suitable colorants are those known in theart for use in various polymeric materials. Exemplary colors imparted bythe colorant include white, black, red, pink, orange, yellow, green,aqua, purple, and blue. In some embodiments, it is desirable level tohave a certain degree of opacity for one or more of the polymericmaterials. The amount of colorant(s) to be used in specific embodimentscan be readily determined by those skilled in the (e.g., to achievedesired color, tone, opacity, transmissivity, etc.).

The shape of the individual polymeric ribbons and polymeric strands in apolymeric netting disclosed herein can depend on a variety of factors.As described above, the polymeric strands, which are lower in heightthan the polymeric ribbons, may exit the die at a faster rate than thepolymeric ribbons and may be oscillating. Therefore, in someembodiments, the polymeric ribbons may be substantially straight, forexample, when no extension force is placed on the polymeric netting asshown in FIGS. 31A, 32A, and 33A, for example. However, depending on thedifferent in height between the polymeric ribbons and strands, theplacement of the polymeric strands on the major surface of the polymericribbons, and the modulus of the materials from which the polymericribbons and polymeric strands are made, both the polymeric ribbons andpolymeric strands may occupy a sinusoidal path in the lengthwisedirection as shown, for example, in FIG. 2. In some embodiments, thepolymeric ribbons may exit the die at a faster rate than the polymericstrands and may be oscillating. In these embodiments, the polymericstrands may appear substantially straight, for example, when noextension force is placed on the polymeric netting.

In some embodiments, a single strand of the polymeric strands or asingle ribbon of the polymeric ribbons in the netting may includedifferent polymeric compositions. For example, one or more of thepolymeric strands in the polymeric netting may have a core made of onepolymeric composition and a sheath of a different polymeric composition.Such nets can be extruded as described in International PatentApplication Publication No. WO 2013/032683 (Ausen et al.), thedisclosure of which is incorporated herein by reference. Nets in whichtheir opposing major surfaces are made from different polymericcompositions are described in International Application No.PCT/US2014/021494, filed Mar. 7, 2014.

As described above in connection with FIG. 8, in some embodiments, thepolymeric ribbons each have a center line bisecting the major surfaceand first and second edges symmetrically disposed on opposite sides ofthe center line, wherein the first edges of the polymeric ribbonscomprise a different composition than the second edges of the polymericribbons. In the illustrated embodiment, the polymeric strands also havea center line bisecting a major surface and first and second edgessymmetrically disposed on opposite sides of the center line, wherein thefirst edges of the polymeric strands comprise a different compositionthan the second edges of the polymeric strands. A polymeric netting suchas that indicated by polymeric netting 90 in FIG. 8 can conveniently bemade, for example, using a shim sequence 3000 shown in FIGS. 27A and27B. FIGS. 27A and 27B show a perspective assembly of a sequence ofshims including shims 3100, 3200, and 3300, described below.

Referring now to FIG. 24, a plan view of shim 3100 is illustrated. Shim3100 has first aperture, 3110 a, second aperture 3110 b, a thirdaperture 3110 c, and a fourth aperture 3110 d. When shim 3100 isassembled with others as shown in FIGS. 27A and 27B, first aperture 3110a will help define first cavity 3012 a, second aperture 3110 b will helpdefine second cavity 3012 b, third aperture 3110 c will help definethird cavity 3012 c, and fourth aperture 3110 d will help define fourthcavity 3012 d. As will be discussed with more particularity below,molten polymer in cavities 3012 a and 3012 d can be extruded intopolymeric ribbons 91 having first and second portions 91 a and 91 b intwo layers, and molten polymer in cavities 3012 b and 3012 c can beextruded into polymeric strands 93 having first and second portions 93 aand 93 b in two layers as shown in FIG. 8.

Shim 3100 has several holes 3147 to allow the passage of, for example,bolts to hold shim 3100 and others to be described below into anassembly. Shim 3100 has dispensing opening 3156 in dispensing surface3167. It might appear that there are no paths from apertures 3110 a and3110 d to dispensing opening 3156, via, for example, passageways 3168 aand 3168 d, but the flows have routes 3068 a and 3068 d in theperpendicular-to-the-plane-of-the-shim dimension when the sequence ofFIG. 27A, for example, is completely assembled. Similar to shim 100,dispensing surface 3167 of shim 3100 has indexing groove 3180,identification notch 3182, and shoulders 3190 and 3192.

Referring now to FIG. 25, a plan view of shim 3200 is illustrated. Shim3200 has first aperture, 3210 a, second aperture 3210 b, third aperture3210 c, and fourth aperture 3210 d. When shim 3200 is assembled withothers as shown in FIGS. 27A and 27B, first aperture 3210 a will helpdefine first cavity 3012 a, second aperture 3210 b will help definesecond cavity 3012 b, third aperture 3210 c will help define thirdcavity 3012 c, and fourth aperture 3210 d with help define fourth cavity3012 d. Analogous to shim 3100, shim 3200 has dispensing surface 3267,and in this particular embodiment, dispensing surface 3267 has indexinggroove 3280. Also analogous to shim 3100, shim 3200 has shoulders 3290and 3292 and holes 3247. There is no passage from any of the cavities todispensing surface 3267 since this shim creates a non-dispensing areaalong the width of the die. Referring again to FIG. 8, shim(s) 3200 areuseful for separating shims 3100 producing polymeric ribbons 91 fromshims 3300 producing polymeric strands 93.

Referring now to FIG. 26, a plan view of shim 3300 is illustrated. Shim3300 has first aperture 3310 a, second aperture 3310 b, third aperture3310 c, and fourth aperture 3310 d. When shim 3300 is assembled withothers as shown in FIGS. 27A and 27B, first aperture 3310 a will helpdefine first cavity 3012 a, second aperture 3310 b will help definesecond cavity 3012 b, third aperture 3310 c will help define thirdcavity 3012 c, and fourth aperture 3310 d with help define fourth cavity3012 d. Analogous to shim 3100, shim 3300 has dispensing surface 3367,and in this particular embodiment, dispensing surface 3367 has indexinggroove 3380 and identification notch 3382. Also analogous to shim 3100,shim 3300 has shoulders 3390 and 3392 and holes 3347. Shim 3300 hasdispensing opening 3356 in dispensing surface 3367. It might appear thatthere are no paths from apertures 3310 b and 3310 c to dispensingopening 3356, via, for example, passageway 3368 b and 3368 c,respectively, but the flows have routes in theperpendicular-to-the-plane-of-the-shim dimension when the sequence ofFIG. 27A, for example, is completely assembled.

Referring now to FIGS. 27A and 27B, a perspective assembly drawing of asequence of shims, collectively 3000, employing the shims of FIGS. 24,25 and 26 so as to produce polymeric netting 90 shown in FIG. 8 isshown. More particularly, proceeding from left to right in FIG. 27B,sequence 3000 includes four instances of shim 3200, four instances ofshim 3300 that can extrude polymeric strands 93, four instances of shim3200, and two instances of shim 3100 that can extrude polymeric ribbons91. Dispensing orifices 3001 and 3003 are separated by shims 3200, whichcauses the separation of polymeric ribbons 91 from polymeric strands 93in the polymeric netting 90. The first dispensing orifices 3001 eachhave a height h3001 to width w3001 aspect ratio of at least three to one(in some embodiments, at least 5:1, 8:1, 10:1, 11:1, 15:1, 20:1, 30:1,or 40:1). In FIG. 27B, the width of the first dispensing orifices can beconsidered to be the width of two shims 3100. As in the embodiment shownin FIG. 12B, the height h3001 of the first dispensing orifices 3001 isat least 2, 2.5, 3, 5, 10, or 20 times larger than the height h3003 ofthe second dispensing orifices. In this embodiment, at least the firstdispensing orifices 3001 are defined by an array of first vestibules,and the die includes a first fluid passageway 3068 a between the firstcavity 3012 a and one of the first vestibules, and a fourth passageway3068 d extending from the fourth cavity 3012 d to the same vestibule,such that the area where the first fluid passageway 3068 a enters thefirst vestibules is below the area where the fourth fluid passageway3068 d enters the first vestibules. The extrusion die also includesfluid passageways extending from one of the cavities with the die to thesecond dispensing orifices. In the illustrated embodiment, the seconddispensing orifices 3003 are defined by an array of second vestibules,and the die includes a second fluid passageway 3068 b between the secondcavity 3012 b and one of the second vestibules, and a third passageway3068 c extending from a third cavity 3012 c to the same vestibule, suchthat the area where the second fluid passageway 3068 b enters the secondvestibules is below the area where the third fluid passageway 3068 centers the second vestibules.

In other embodiments in which the first edges of the polymeric ribbonscomprise a different composition than the second edges of the polymericribbons, the polymeric netting can be surface treated with a surfactant(e.g., in an amount between about 0.05 and 0.5 weight percent). If asurfactant is used, it can be an internal additive in a polymericcomposition that migrates to the surface, or a surfactant can be appliedto the web by any conventional means (e.g., spraying, printing, dipping,or brush coating). Polymer compositions (e.g., those providing secondportions 91 b and 93 b shown in FIG. 8) may be selected to behydrophilic or to include a surfactant, or a surfactant can be appliedto a major surface of the polymeric netting to impart a desired level ofwettability and hydrophilicity to at least a portion of the polymericnetting for certain applications.

In any of the aforementioned embodiments of the polymeric nettingaccording to and/or made from the method according to the presentdisclosure, the distance between bonds can be in a range from 0.5 mm to20 mm (in some embodiments, in a range from 0.5 mm to 10 mm). Also, inany of the aforementioned embodiments, the polymeric netting accordingto the present disclosure or made from the method disclosed herein canhave a basis weight in a range from 5 g/m² to 750 g/m² (in someembodiments, 5 g/m² to 400 g/m² or 10 g/m² to 200 g/m²). In someembodiments, the polymeric netting disclosed herein in any of theaforementioned embodiments has a thickness up to 4 mm (in someembodiments, up to 3.5 mm, 3 mm, 2 mm, 1 mm, 0.75 mm, or less than 0.75mm), in some embodiments, in a range from 10 micrometers to 4 mm, 10micrometers to 3.5 mm, 10 micrometers to 3 mm, 10 micrometers to 2 mm,10 micrometers to 1 mm, 10 micrometers to 750 micrometers, 10micrometers to less than 750 micrometers, 10 micrometers to 749micrometers, 10 micrometers to 700 micrometers, or 10 micrometers to 650micrometers.

The polymeric netting according to and/or made according to the presentdisclosure is useful, for example, in absorbent articles. Accordingly,the present disclosure provides an absorbent article including apolymeric netting according to the present disclosure. Personal careabsorbent articles, such as diapers, training pants, adult incontinencegarments, and feminine hygiene pads (e.g., sanitary napkins andpantyliners) and wound care absorbent articles (e.g., wound dressingsand bandages) are often constructed using a skin-facing fluid pervioustopsheet, a garment-facing fluid impervious backsheet, and an absorbentcore positioned therebetween. An exploded schematic view of an exampleof an embodiment of an absorbent article 4000 according to the presentdisclosure is shown in FIG. 28. In absorbent articles according to thepresent disclosure, the absorbent core 4060 is typically interposedbetween the polymeric netting and the backsheet 4040. The polymericnetting can be useful, for example as at least one of a topsheet 4010 oracquisition/distribution layer 4080. In the illustrated embodiment, thepolymeric netting forms topsheet 4010. When used as anacquisition/distribution layer 4080, the polymeric netting may also belocated between the absorbent core 4060 and the backsheet 4040 or withinthe absorbent core 4060 (e.g., between two tissue sheets 4090).

Polymeric netting according to the present disclosure advantageously canbe used as a topsheet in an absorbent article. Referring to FIG. 28, thetopsheet 4010 is the layer against the user's skin and so the firstlayer in contact with liquid or other exudate from the user. Thetopsheet desirably serves several purposes including keeping theabsorbent material contained within the article, allowing fluids torapidly pass through to the absorbent core, providing a skin friendly,comfortable contact surface for the skin contacted by the article,keeping the skin clean and dry, and helping to prevent absorbed fluidfrom coming into contact with the skin. When used as a topsheet 4010 forhygiene articles, the polymeric netting may have a configuration asshown in any one of FIGS. 1 to 4 and 8, for example. In theseconfigurations, the polymeric ribbons 1 each have a center line 4bisecting the first major surface 2 and first and second edges 6, 8symmetrically disposed on opposite sides of the center line 4, whereinthe polymeric strand 3 is bonded to the first major surface 2 at alocation closer to the first edges 6 than the second edges 8. In otherwords, referring to FIG. 3, the polymeric strands 33 are all disposedtoward the same first edges of the polymeric ribbons 31, 41 so that boththe polymeric ribbons and polymeric strands can contact absorbent 47 inarticle 30. This configuration also provides greater surface area on oneside of the polymeric netting 40 for adhesive bonding the netting to theabsorbent. However, in other embodiments, the configuration shown inFIGS. 5, 6, and 7 may be useful.

In any of the configurations shown in FIGS. 1 to 7, the Examples belowindicate that in some embodiments, the polymeric netting can have atleast one of the following features: capable of rapid fluid uptake,directs the fluid in the machine direction of the material, offers ahigh degree of resistance to rewet, presents a dry to the touch skinfacing surface after exposure to fluids, and due to the flexibility ofthe ribbon like element provides a cleansing action to the skin, drivenby natural body motions, resulting in cleaner and drier skin for thewearer of an absorbent hygiene article utilizing this new topsheetmaterial.

In an absorbent article according to the present disclosure, thebacksheet (e.g., 4040 shown in FIG. 28), sometimes referred to as theouter cover, is the farthest layer from the user. The backsheet istypically formed of a thin thermoplastic film (e.g., polyethylene film)which is substantially impermeable to liquid. The backsheet functions toprevent body exudates absorbed by the absorbent core from wetting orsoiling the wearer's clothing, bedding, or other materials contactingthe absorbent article. A variety of materials for the backsheet may besuitable in an absorbent article according to the present disclosure.For example, the backsheet may comprise a polyethylene film (e.g.,having an initial thickness of about 0.5 mil (0.012 millimeter) to about5.0 mil (0.12 millimeter)), a woven or nonwoven fibrous web constructedor treated to impart the desired level of liquid impermeability, alaminate of a woven or nonwoven fabric and thermoplastic film, or avapor or gas permeable microporous “breathable” material that issubstantially impermeable to liquid. Films useful as backsheets, forexample, may be embossed and/or matte finished to provide a moreaesthetically pleasing appearance.

In an absorbent article according to the present disclosure, theabsorbent core (e.g., 4060 as shown in FIG. 28) typically includes anatural, synthetic, or modified natural organic polymer that can absorband hold liquids (e.g., aqueous liquids). In some embodiments, thepolymer is crosslinked. The term “crosslinked” refers to any means foreffectively rendering normally water-soluble materials substantiallywater insoluble but swellable. Such absorbent materials are usuallydesigned to quickly absorb liquids and hold them, usually withoutrelease. The size and the absorbent capacity of the absorbent core istypically compatible with the size of the intended wearer and the liquidloading imparted by the intended use of the absorbent article. Variousabsorbents may be useful, for example, a cellulosic material (e.g., woodpulp fluff), hydrophilic, synthetic meltblown fibers, superabsorbentpolymer (SAP), an acrylic foam absorbent (e.g., foams described in U.S.Pat. No. 5,817,704 (Shiveley et al.) and the references cited therein,prepared, for example, by polymerization of high internal phaseemulsions), and any combination thereof. Absorbent materials may bezoned and their compositions chosen to move liquids away from theoriginal location of the incoming insult to more remote storagelocations. In some embodiments, the absorbent core can include one ormore substantially hydrophilic tissue sheets 4090 to help maintain theintegrity, for example, of the structure of the absorbent core. Thetissue sheet(s), which may be one tissue sheet wrapped around to providetwo major facing surfaces of the absorbent core, can include absorbentcellulosic material (e.g., creped wadding or a high wet-strengthtissue). In some embodiments, the tissue sheet can be configured torapidly distribute liquid over the absorbent core. In these embodiments,the tissue sheet may be considered a distribution layer, which movesfluid from the point of initial deposition to the location where storageis desired.

Some absorbent articles include an acquisition layer 4080, which can beuseful for quickly accepting an incoming insult and either absorb, hold,channel, or otherwise manage the liquid so that it does not leak outsidethe article. The acquisition layer may also be referred to, for example,as a surge layer, intake layer, transfer layer, or transport layer. Anacquisition layer is generally capable of handling an incoming insult ofbetween about 60 and 100 milliliters (mL) at an insult volumetric flowrate of from about 5 to 20 mL/second, for infants, for example. Anacquisition layer is generally subjacent the topsheet at the surfaceopposite the user's skin. Various woven and nonwoven webs and foams canbe used to construct an acquisition layer. Acquisition layers may becomposed of a substantially hydrophobic material, and the hydrophobicmaterial may optionally be treated with a surfactant or otherwiseprocessed to impart a desired level of wettability and hydrophilicity.In some embodiments, acquisition layer 4080 can have a generally uniformthickness and cross-sectional area. The polymeric netting according tothe present disclosure may be useful as an acquisition layer incombination with a conventional topsheet (e.g., a nonwoven or anapertured film as described below) as a topsheet in combination with aconventional acquisition layer, or in some embodiments as a replacementfor both a conventional topsheet and acquisition layer. In other words,when the polymeric netting according to the present disclosure is usedas a topsheet, the need for the acquisition layer may be eliminated.

Suitable conventional attachment techniques may be useful for assemblingan absorbent article according to the present disclosure. When used as atopsheet 4010, the polymeric netting according to the present disclosuremay be attached to the absorbent core 4060 or the acquisition layer 4080(if used) using at least one of adhesive bonding (e.g., usingwater-based, solvent-based, or thermally activated adhesives), thermalbonding, ultrasonic bonding, needling, or pin aperturing. When used asan acquisition layer 4080, the polymeric netting according to thepresent disclosure can be attached to both the conventional topsheet andthe absorbent core 4060 also using any one of these methods. If adhesivebonding is used, the amount of adhesive add-on should be sufficient toprovide the desired level(s) of bonding, without excessively restrictingthe flow of liquid into the absorbent core 4060.

When used as a topsheet in an absorbent article, the polymeric nettingcan overcome disadvantages of conventional topsheet materials. Fordiapers, incontinence articles, and feminine hygiene pads theconventional types of topsheet, generally fall into two main groups:nonwovens and apertured films. Nonwovens have the advantage of beingsoft and cloth-like in feel. Nonwovens can be made hydrophilic (e.g., bytreating with surfactant) to allow rapid fluid transport through thenonwoven to the absorbent. Such hydrophilic materials tend to cause userto feel wetness possibly due to small amounts of fluid being retained inthe nonwoven. Retained fluid in the nonwoven also makes the fluid morevisible, which is undesirable. Some hydrophilic nonwovens also have atendency to direct fluids toward the lateral edges of the pad,potentially contributing to side leakage. To achieve the goals ofsoftness and dry feel in nonwoven topsheets, sometimes the nonwoven ismade of hydrophobic fibers. The use of hydrophobic fibers typicallyresults in improved dry feel, but hydrophobic nonwovens may not allowrapid fluid transport into the pad. Sometimes hydrophobic nonwovens cancause fluid to pool on the surface of the pad, which can also result inleakage. An advantage of using apertured films as topsheets forabsorbent articles is that they provide a relatively clean and drysurface as exudates passes through the film layer and into the interiorof the pad. A drawback of such film-based topsheets is that they do notprovide the degree of softness and comfort that a nonwoven topsheetprovides.

In use as an absorbent article, the structure of the polymeric nettingaccording to the present disclosure, with its polymeric ribbonsseparated from each other by polymeric strands that are significantlyshorter, creates a plurality of air flow channels along the lengths ofthe polymeric ribbons and that allow air to circulate between theabsorbent and the skin of the wearer even while the first edges of thepolymeric ribbons, distal from the absorbent, are in contact with theskin of the wearer. These channels, which are absent from conventionaltopsheet materials, can provide a feeling of dryness and comfort. Thefirst edges of the polymeric ribbons, which extend above the height ofthe polymeric strands, are free to flex and bend in response to anylateral forces exerted on them (e.g., through movement of the user). Theflexibility of the polymeric ribbons adds to a feeling of softnessagainst the user's skin. It is also believed that the ability of thepolymeric ribbons to bend allows them to provide a cleansing action whenthe absorbent article is shifted slightly in its position relative tothe user's skin. When the first edges of the polymeric ribbons contactthe user's skin, small movements of the user (e.g., walking) can causethe polymeric ribbons to bend which may allow the polymeric ribbons tocome into contact with a drop of liquid on a user's skin and draw itdown to contact the absorbent. In this way, the polymeric ribbons serveas miniature squeegees for removing liquid from the skin.

Also, as shown in Table 1 in the Examples below, the structure of thepolymeric netting according to the present disclosure, with itspolymeric ribbons separated from each other by polymeric strands thatare significantly shorter allows fluid to be distributed in an absorbentarticle in the longitudinal direction to a much greater extent than in aconventional pad. Better distribution of fluid can prevent leakage in anabsorbent article.

With the polymeric nettings according to the present disclosure and/ormade according to a method disclosed herein, it may be useful to havethe polymeric ribbons spread apart from one another to a greater extentin one portion of the absorbent article than in the other (e.g., usingthe methods described above.) Attaching the spread polymeric netting tothe absorbent or another layer of the article is useful for holding theweb in this spread open condition. Spreading in certain locations allowsthe performance of the polymeric netting to be tailored to provide, forexample, a different uptake rate and other performance characteristicsnear the lateral centerline of the article than near the lateral edgesof the article. However, in some embodiments it may be desired to spreadthe web in the cross direction uniformly across the entire width of thepolymeric netting.

The polymeric compositions selected for the polymeric ribbons andpolymeric strands when the polymeric netting is used in an absorbentarticle may be hydrophobic or hydrophilic as desired. Additionalmaterial modifiers (e.g. surfactants) can be added to at least one ofthe polymeric ribbons or polymeric strands to change theirhydrophilicity or tailor how a liquid interacts with the polymericnetting. For example, the polymeric ribbons may be made relativelyhydrophilic for quicker fluid penetration through the polymeric nettingwhile the polymeric strands may be made hydrophobic to minimize rewet.Or various constructions of the polymeric netting such as those shown inFIGS. 6 and 8 can be useful for tailoring the hydrophilicity of thepolymeric netting. For example, in FIG. 6, if polymeric netting 70 ispositioned on an absorbent such that polymeric ribbons 71 are extendingaway from the absorbent and polymeric ribbons 81 are in contact with theabsorbent, polymeric ribbons 71 may be made hydrophilic to draw fluidinto the absorbent, and polymeric ribbons 81 may be made hydrophobic tominimize rewet. In FIG. 8, if polymeric netting 90 is positioned on anabsorbent such that the second portions of the polymeric ribbons andpolymeric strands 91 b and 93 b are in contact with the absorbent, thefirst portions 91 a of at least the polymeric ribbons may be madehydrophilic to draw fluid into the absorbent, and at least one of thesecond portions 91 b, 93 b of the polymeric ribbons or polymeric strandsmay be made hydrophobic to minimize rewet. In some embodiments, it mayalso be desirable to have the opposite pattern of hydrophilicity, forexample, in which the polymeric ribbons or portions thereof that extendaway from the absorbent and toward the skin are more hydrophobic thanthe polymeric ribbons, strands, or portions thereof positioned on theabsorbent. Variations of these methods may be useful to providegradients of hydrophilicity in the polymeric netting. These gradients ofhydrophilicity and hydrophobicity may also be useful in otherapplications for the polymeric nettings described below, for example,that do not include an absorbent.

Polymeric netting according to the present disclosure may also beuseful, for example, as part of a cleaning device, such as a wipe or asponge. The cleansing action provided by the polymeric ribbons describedabove in connection with absorbent articles may also make polymericnettings disclosed herein useful for cleaning hard surfaces. Many timescleaning sheets are too flat over the surface being cleaned andtherefore only the leading edge of the cleaning sheet will load withmaterial. A variety of techniques have been disclosed to raise portionsof the cleaning sheet or to have recessed portions of the cleaning sheetto more effectively get dirt, dust and debris to capture and retainacross the working surface; see, e.g., U.S. Pat. No. 7,757,334 (Patel etal.) and U.S. Pat. Appl. Pub. Nos. 2007-0136967 (Tochacek et al.) and2009-0144923 (Tuman et al.). It is believed that the first edges of thepolymeric ribbons can be useful at the working surface of a cleaningwipe or sponge to scoop up debris during use, and the channels in thepolymeric netting structure can help deliver the debris to a retainingsurface within the wipe or sponge.

Polymeric nettings according to the present disclosure are also useful,for example, as elastic wraps. Such wraps can be useful, for example, inmedical and athletic applications. For example, a polymeric nettingaccording to the present disclosure can be useful in compressiontherapy, in which the application of external pressure to vascularelements increases interstitial pressure. The resulting improvement invenous return and alleviation of various symptoms (e.g., venousulcerations and edema) makes compression therapy a useful treatment invenous and lymphatic disease, for example. Polymeric netting accordingto the present disclosure in use as a wrap 5000 is illustrated in FIG.29. The net structure of wrap 5000 allows for two-way stretching andhigh breathability. The wrap may be secured using any conventionalfastener (e.g., adhesive or mechanical fasteners).

Polymeric nettings useful as wraps may have any of the configurationsshown in FIGS. 1 to 8. In use as a wrap, when the polymeric ribbons inthe polymeric nettings disclosed herein in any of their embodiments arepositioned in contact with the wearer's skin, the portions of thepolymeric ribbons that extend above the height of the polymeric strandsare free to flex and bend in response to any lateral forces exerted onthe tops of these ribbons. In other words, the polymeric ribbons ends ofthe polymeric ribbons are free to bend over the polymeric strands.Because of this movement, it is believed that micromuscular movementsduring wear are more comfortable than with the elastic wraps that do nothave this deflection behavior. The deflection of the polymeric ribbonsmakes the compression wrap feel soft and spongy to the touch.

Furthermore, when the polymeric nettings disclosed herein in any oftheir embodiments are used as wraps, the polymeric ribbons on one majorsurface of the netting may be interleaved with polymeric ribbons on theopposite surface of the polymeric netting when the polymeric netting isin a wrapped configuration. Depending on the materials that are used inthe netting, these interleaved ribbons may exhibit adhesion to eachother and may assist with the fastening of the wrap around the wearer.The constructions of FIGS. 5 and 6 (e.g., Examples 2 to 4) may exhibitthis behavior, for example.

In embodiments in which the polymeric ribbons and polymeric strands aredifferent colors, polymeric nettings useful as wraps, for example, canhave unique aesthetic appeal. Using different colors in the polymericribbons from the polymeric strands can result in an iridescence in whichthe color of the wrap appears to be different depending upon the angleof viewing. Thus, in some embodiments, polymeric nettings according tothe present disclosure useful as wraps have polymeric ribbons that are adifferent color from the polymeric strands. When different polymericribbons 31 and 41 or 71 and 81 shown in FIGS. 3 and 6, for example, arepresent in the polymeric netting, it may be useful for the differentpolymeric ribbons to be different colors.

In the embodiment shown in FIG. 6, for example, three different colorsof polymer may be used to make polymeric ribbons 71, polymeric strands73, and polymeric ribbons 81. When the polymeric ribbons 71 are viewedat an angle, the polymeric netting 70 may appear to be predominantly thecolor of ribbons 71. When the polymeric ribbons 81 are viewed at anangle, the polymeric netting 70 may appear to be predominantly the colorof ribbons 81, and when the polymeric netting is viewed straight on(e.g., as in the configuration schematically shown in FIG. 6) all threecolors may be visible.

In some applications, the polymeric netting according to the presentdisclosure and/or made according to a method disclosed herein can beused, for example, to provide spacers between filtering layers forfiltration packs and/or to provide rigidity and support for filtrationmedia. In some embodiments, several layers of the polymeric netting areused, where each layer is positioned to provide optimal filtering. Also,in some embodiments, the elastic feature of some polymeric nettingsdisclosed herein can accommodate expansion of the filter as the filterfills up.

In addition to the applications described above, polymeric nettingsaccording to the present disclosure and/or made according to the methoddisclosed herein may be useful in a variety of other applications,including as a surface layer for surgical drapes and gowns, castpadding, tapes (including for medical applications), pest controlarticles (e.g., mosquito nettings), geotextile applications (e.g.,erosion control textiles), water/vapor management in clothing,reinforcement for nonwoven articles (e.g., paper towels), self-bulkingarticles (e.g., for packaging) where the polymeric netting thickness isincreased by stretching polymeric nettings with polymeric ribbons andpolymeric strands having very different moduli or elasticities, floorcoverings (e.g., rugs and temporary mats), grip supports (e.g., fortools and athletic articles), and pattern-coated adhesives.

In some embodiments, the polymeric netting according to and/or madeaccording to the present disclosure is joined to a carrier for ease ofhandling or for making a laminate for a selected application. Thepolymeric netting may be joined to a carrier, for example, by lamination(e.g., extrusion lamination), adhesives (e.g., pressure sensitiveadhesives), or other bonding methods (e.g., ultrasonic bonding,compression bonding, or surface bonding).

The carrier may be continuous (i.e., without any through-penetratingholes) or discontinuous (e.g. comprising through-penetratingperforations or pores). The carrier may comprise a variety of suitablematerials including woven webs, non-woven webs (e.g., spunbond webs,spunlaced webs, airlaid webs, meltblown web, and bonded carded webs),textiles, plastic films (e.g., single- or multilayered films, coextrudedfilms, laterally laminated films, or films comprising foam layers), andcombinations thereof. In some embodiments, the carrier is a fibrousmaterial (e.g., a woven, nonwoven, or knit material). Examples ofmaterials for forming thermoplastic films or thermoplastic fibers for afibrous carrier include polyolefins (e.g., polyethylene, polypropylene,polybutylene, ethylene copolymers, propylene copolymers, butylenecopolymers, and copolymers and blends of these polymers), polyesters,and polyamides. The fibers may also be multi-component fibers, forexample, having a core of one thermoplastic material and a sheath ofanother thermoplastic material. In some embodiments, the carriercomprises multiple layers of nonwoven materials with, for example, atleast one layer of a meltblown nonwoven and at least one layer of aspunbonded nonwoven, or any other suitable combination of nonwovenmaterials. For example, the carrier may be a spunbond-meltbond-spunbond,spunbond-spunbond, or spunbond-spunbond-spunbond multilayer material.Or, the carrier may be a composite web comprising a nonwoven layer and adense film layer. Useful carriers may have any suitable basis weight orthickness that is desired for a particular application. For a fibrouscarrier, the basis weight may range, e.g., from at least about 5, 8, 10,20, 30, or 40 grams per square meter, up to about 400, 200, or 100 gramsper square meter. The carrier may be up to about 5 mm, about 2 mm, orabout 1 mm in thickness and/or at least about 0.1, about 0.2, or about0.5 mm in thickness.

In some embodiments where the polymeric netting is made from athermoplastic, the thermoplastic can be joined to a fibrous web carrierusing surface bonding or loft-retaining bonding techniques. The term“surface-bonded” when referring to the bonding of fibrous materialsmeans that parts of fiber surfaces of at least portions of fibers aremelt-bonded to at least a portion of the polymeric netting, in such amanner as to substantially preserve the original (pre-bonded) shape ofthe polymeric netting, and to substantially preserve at least someportions of the polymeric netting in an exposed condition, in thesurface-bonded area. Quantitatively, surface-bonded fibers may bedistinguished from embedded fibers in that at least about 65% of thesurface area of the surface-bonded fiber is visible above the polymericnetting in the bonded portion of the fiber. Inspection from more thanone angle may be necessary to visualize the entirety of the surface areaof the fiber. The term “loft-retaining bond” when referring to thebonding of fibrous materials means a bonded fibrous material comprises aloft that is at least 80% of the loft exhibited by the material priorto, or in the absence of, the bonding process. The loft of a fibrousmaterial as used herein is the ratio of the total volume occupied by theweb (including fibers as well as interstitial spaces of the materialthat are not occupied by fibers) to the volume occupied by the materialof the fibers alone. If only a portion of a fibrous web has thepolymeric netting bonded thereto, the retained loft can be easilyascertained by comparing the loft of the fibrous web in the bonded areato that of the web in an unbonded area. It may be convenient in somecircumstances to compare the loft of the bonded web to that of a sampleof the same web before being bonded, for example, if the entirety offibrous web has the polymeric netting bonded thereto. In some of theseembodiments, the joining comprises impinging heated gaseous fluid (e.g.,ambient air, dehumidified air, nitrogen, an inert gas, or other gasmixture) onto a first surface of the fibrous web carrier while it ismoving; impinging heated fluid onto a major surface of the polymericnetting while the continuous web is moving; and contacting the firstsurface of the fibrous web with the polymeric netting so that the firstsurface of the fibrous web is melt-bonded (e.g., surface-bonded orbonded with a loft-retaining bond) to the polymeric netting. Impingingheated gaseous fluid onto the first surface of the fibrous web andimpinging heated gaseous fluid on a major surface of the polymericnetting may be carried out sequentially or simultaneously. Furthermethods and apparatus for joining a continuous web to a fibrous carrierweb using heated gaseous fluid may be found in U.S. Pat. Appl. Pub. Nos.2011/0151171 (Biegler et al.) and 2011/0147475 (Biegler et al.).

In some embodiments wherein the polymeric netting is joined to acarrier, one or more zones of the carrier may comprise one or moreelastically extensible materials extending in at least one directionwhen a force is applied and returning to approximately their originaldimension after the force is removed. In some embodiments, at least theportion of the carrier joined to the multiple strands of the backing orloop material is not stretchable. In some embodiments, the portion ofcarrier joined to the multiple strands will have up to a 10 (in someembodiments, up to 9, 8, 7, 6, or 5) percent elongation in the CD. Insome embodiments, such constructions may be subjected to mechanicalactivation (e.g., ring rolling) to render them elastomeric. In someembodiments, the carrier may be extensible but nonelastic. In otherwords, the carrier may have an elongation of at least 5, 10, 15, 20, 25,30, 40, or 50 percent but substantially no recovery from the elongation(e.g., up to 10 or 5 percent recovery). Suitable extensible carriers mayinclude nonwovens (e.g., spunbond, spunbond meltblown spunbond, orcarded nonwovens). In some embodiments, the nonwoven may be a highelongation carded nonwoven (e.g., HEC). In some embodiments, the carrieris not pleated.

Some Embodiments of the Disclosure

In a first embodiment, the present disclosure provides a polymericnetting comprising polymeric ribbons and polymeric strands, each of thepolymeric ribbons and strands having a length and width, wherein thelength is the longest dimension and the width is the shortest dimension,wherein the polymeric ribbons have a height-to-width aspect ratio of atleast five to one, a major surface that is intermittently bonded to onlyone polymeric strand at multiple, spaced-apart bonding sites, and aheight that is at least two times greater than a height of the onepolymeric strand.

In a second embodiment, the present disclosure provides the polymericnetting of the first embodiment, wherein the polymeric ribbons each havea center line bisecting the major surface and first and second edgessymmetrically disposed on opposite sides of the center line, wherein themajor surface is intermittently bonded to only one polymeric strand at alocation closer to the first edge than the second edge.

In a third embodiment, the present disclosure provides the polymericnetting of the first or second embodiment, wherein the polymeric ribbonseach have a center line bisecting the major surface and first and secondedges symmetrically disposed on opposite sides of the center line,wherein the polymeric netting has first and second opposing majorsurfaces transverse to the major surfaces of the polymeric ribbons,wherein the first major surface of the polymeric netting comprises thefirst edges of the polymeric ribbons, and wherein the second majorsurface comprises the second edges of the polymeric ribbons and portionsof at least some of the polymeric strands.

In a fourth embodiment, the present disclosure provides the polymericnetting of the first embodiment, wherein the polymeric ribbons each havea center line bisecting the major surface, and wherein the major surfaceis intermittently bonded to only one polymeric strand at a locationincluding the center line.

In a fifth embodiment, the present disclosure provides the polymericnetting of the first or fourth embodiment, wherein the polymeric ribbonsand polymeric strands are vertically centered.

In a sixth embodiment, the present disclosure provides the polymericnetting of the first, second, fourth, or fifth embodiment, wherein thepolymeric ribbons each have a center line bisecting the major surfaceand first and second edges symmetrically disposed on opposite sides ofthe center line, wherein the polymeric netting has first and secondopposing major surfaces transverse to the major surfaces of thepolymeric ribbons, wherein the first major surface of the polymericnetting comprises the first edges of the polymeric ribbons, and whereinthe second major surface comprises the second edges of the polymericribbons, and wherein neither the first nor second major surfacescomprise a portion of the polymeric strands.

In a seventh embodiment, the present disclosure provides the polymericnetting of the first embodiment, wherein the polymeric ribbons each havea center line bisecting the major surface and first and second edgessymmetrically disposed on opposite sides of the center line, wherein themajor surface of a first portion of the polymeric ribbons is bonded toonly one polymeric strand at a location closer to the first edge thanthe second edge and the major surface of a second portion of thepolymeric ribbons is bonded to only one polymeric strand at a locationcloser to the second edge than the first edge.

In an eighth embodiment, the present disclosure provides the polymericnetting of the first, fourth, or seventh embodiment, wherein thepolymeric ribbons each have a center line bisecting the major surfaceand first and second edges symmetrically disposed on opposite sides ofthe center line, wherein the polymeric netting has first and secondopposing major surfaces transverse to the major surfaces of thepolymeric ribbons, wherein the first major surface of the polymericnetting comprises the first edges of a first portion of the polymericribbons, wherein the second major surface comprises the second edges ofthe polymeric ribbons, wherein the first portion of the polymericribbons does not extend to the second major surface, and wherein thesecond portion of the polymeric ribbons does not extend to the firstmajor surface.

In a ninth embodiment, the present disclosure provides the polymericnetting of any one of the first to eighth embodiments, wherein thepolymeric ribbons each have a center line bisecting the major surfaceand first and second edges symmetrically disposed on opposite sides ofthe center line, wherein the first edges of the polymeric ribbonscomprise a different composition than the second edges of the polymericribbons.

In a tenth embodiment, the present disclosure provides the polymericnetting of any one of the first to ninth embodiments, wherein thepolymeric ribbons and polymeric strands alternate in at least a portionof the polymeric netting.

In an eleventh embodiment, the present disclosure provides the polymericnetting of any one of the first to tenth embodiments, wherein thepolymeric strands and polymeric ribbons do not intersect each other.

In a twelfth embodiment, the present disclosure provides the polymericnetting of any one of the first to eleventh embodiments, wherein theheight-to-width aspect ratio of at least some of the polymeric ribbonsis greater than 7 to 1.

In a thirteenth embodiment, the present disclosure provides thepolymeric netting of any one of the first to twelfth embodiments,wherein the height of at least some of the polymeric ribbons is greaterthan 750 micrometers.

In a fourteenth embodiment, the present disclosure provides thepolymeric netting of any one of the first to twelfth embodiments,wherein the height of at least some of the polymeric ribbons is lessthan 750 micrometers.

In a fifteenth embodiment, the present disclosure provides the polymericnetting of any one of the first to fourteenth embodiments, wherein atleast some of the polymeric ribbons have a different color than at leastsome of the polymeric strands.

In a sixteenth embodiment, the present disclosure provides the polymericnetting of any one of the first to fifteenth embodiments, wherein atleast some of the polymeric ribbons have a different polymericcomposition than at least some of the polymeric strands.

In a seventeenth embodiment, the present disclosure provides thepolymeric netting of any one of the first to sixteenth embodiments,wherein the polymeric ribbons are elastic, the polymeric strands areelastic, or both the polymeric ribbons and the polymeric strands areelastic.

In an eighteenth embodiment, the present disclosure provides thepolymeric netting of any one of the first to seventeenth embodiments,wherein the polymeric ribbons are substantially straight.

In a nineteenth embodiment, the present disclosure provides thepolymeric netting of any one of the first to eighteenth embodiments,wherein the polymeric ribbons do not have a uniform height.

In a twentieth embodiment, the present disclosure provides an absorbentarticle having a fluid intake surface comprising the polymeric nettingof any one of the first to nineteenth embodiments.

In a twenty-first embodiment, the present disclosure provides theabsorbent article of the twentieth embodiment, wherein the fluid intakesurface is a topsheet, and wherein the absorbent article furthercomprises a liquid impermeable backsheet and an absorbent core betweenthe topsheet and the backsheet.

In a twenty-second embodiment, the present disclosure provides anabsorbent article comprising a polymeric netting, a liquid impermeablebacksheet, and an absorbent core, wherein the polymeric nettingcomprises polymeric ribbons and polymeric strands, each of the polymericribbons and strands having a length and width, wherein the length is thelongest dimension and the width is the shortest dimension, wherein thepolymeric ribbons have a height-to-width aspect ratio of at least threeto one, a major surface that is intermittently bonded multiple times toa polymeric strand, and a height that is greater than a height of theone polymeric strand, and wherein the absorbent core is between thepolymeric netting and the backsheet, wherein the polymeric netting isbetween the absorbent core and the backsheet, or wherein the polymericnetting is within the absorbent core.

In a twenty-third embodiment, the present disclosure provides theabsorbent article of the twenty-second embodiment, wherein the polymericnetting is a topsheet.

In a twenty-fourth embodiment, the present disclosure provides theabsorbent article of the twenty-second embodiment, wherein the polymericnetting is an acquisition layer between a topsheet and the absorbentcore.

In a twenty-fifth embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to twenty-fourthembodiments, wherein the polymeric ribbons each have a center linebisecting the major surface and first and second edges symmetricallydisposed on opposite sides of the center line, wherein the major surfaceis intermittently bonded to only one polymeric strand at a locationcloser to the first edge than the second edge.

In a twenty-sixth embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to twenty-fifthembodiments, wherein the polymeric ribbons each have a center linebisecting the major surface and first and second edges symmetricallydisposed on opposite sides of the center line, wherein the polymericnetting has first and second opposing major surfaces transverse to themajor surfaces of the polymeric ribbons, wherein the first major surfaceof the polymeric netting comprises the first edges of the polymericribbons, and wherein the second major surface comprises the second edgesof the polymeric ribbons and portions of at least some of the polymericstrands.

In a twenty-seventh embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to twenty-fifthembodiments, wherein the polymeric ribbons each have a center linebisecting the major surface, and wherein the major surface isintermittently bonded to only one polymeric strand at a locationincluding the center line.

In a twenty-eighth embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to twenty-fourth ortwenty-seventh embodiments, wherein the polymeric ribbons and polymericstrands are vertically centered.

In a twenty-ninth embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to twenty-fourth,twenty-seventh, or twenty-eighth embodiment, wherein the polymericribbons each have a center line bisecting the major surface and firstand second edges symmetrically disposed on opposite sides of the centerline, wherein the polymeric netting has first and second opposing majorsurfaces transverse to the major surfaces of the polymeric ribbons,wherein the first major surface of the polymeric netting comprises thefirst edges of the polymeric ribbons, and wherein the second majorsurface comprises the second edges of the polymeric ribbons, and whereinneither the first nor second major surfaces comprise a portion of thepolymeric strands.

In a thirtieth embodiment, the present disclosure provides the absorbentarticle of any one of the twenty-second to twenty-fourth embodiments,wherein the polymeric ribbons each have a center line bisecting themajor surface and first and second edges symmetrically disposed onopposite sides of the center line, wherein the major surface of a firstportion of the polymeric ribbons is bonded to only one polymeric strandat a location to the first edge than the second edge and the majorsurface of a second portion of the polymeric ribbons is bonded to onlyone polymeric strand at a location closer to the second edge than thefirst edge.

In a thirty-first embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to twenty-fourth orthirtieth embodiments, wherein the polymeric ribbons each have a centerline bisecting the major surface and first and second edgessymmetrically disposed on opposite sides of the center line, wherein thepolymeric netting has first and second opposing major surfacestransverse to the major surfaces of the polymeric ribbons, wherein thefirst major surface of the polymeric netting comprises the first edgesof a first portion of the polymeric ribbons, wherein the second majorsurface comprises the second edges of the polymeric ribbons, wherein thefirst portion of the polymeric ribbons does not extend to the secondmajor surface, and wherein the second portion of the polymeric ribbonsdoes not extend to the first major surface.

In a thirty-second embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to thirty-firstembodiments, wherein the polymeric ribbons each have a center linebisecting the major surface and first and second edges symmetricallydisposed on opposite sides of the center line, wherein the first edgesof the polymeric ribbons comprise a different composition than thesecond edges of the polymeric ribbons.

In a thirty-third embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to thirty-secondembodiments, wherein the polymeric ribbons and polymeric strandsalternate in at least a portion of the polymeric netting.

In thirty-fourth embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to thirty-thirdembodiments, wherein the polymeric strands and polymeric ribbons do notintersect each other.

In a thirty-fifth embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to thirty-fourthembodiments, wherein the height-to-width aspect ratio of at least someof the polymeric ribbons is at least 5 to 1.

In a thirty-sixth embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to thirty-fifthembodiments, wherein the height of at least some of the polymericribbons is greater than 750 micrometers.

In a thirty-seventh embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to thirty-fifthembodiments, wherein the height of at least some of the polymericribbons is less than 750 micrometers.

In a thirty-eighth embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to thirty-seventhembodiments, wherein at least some of the polymeric ribbons have adifferent color than at least some of the polymeric strands.

In a thirty-ninth embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to thirty-eighthembodiments, wherein at least some of the polymeric ribbons have adifferent polymeric composition than at least some of the polymericstrands.

In a fortieth embodiment, the present disclosure provides the absorbentarticle of any one of the twenty-second to thirty-ninth embodiments,wherein the polymeric ribbons are elastic, the polymeric strands areelastic, or both the polymeric ribbons and the polymeric strands areelastic.

In forty-first embodiment, the present disclosure provides the absorbentarticle of any one of the twenty-second to fortieth embodiments, whereinthe polymeric ribbons are substantially straight.

In a forty-second embodiment, the present disclosure provides theabsorbent article of any one of the twenty-second to forty-firstembodiments, wherein the polymeric ribbons do not have a uniform height.

In a forty-third embodiment, the present disclosure provides anextrusion die comprising at least one cavity, a dispensing surface, andfluid passageways between the at least one cavity and the dispensingsurface, wherein the dispensing surface has an array of first dispensingorifices separated by an array of second dispensing orifices, whereinthe first dispensing orifices, second dispensing orifices, and any otherdispensing orifices are arranged in a single row across the dispensingsurface, wherein the first and second dispensing orifices each have atop edge, a bottom edge, a height that is the distance between the topedge and the bottom edge, and a width, wherein the first dispensingorifices each have a height-to-width aspect ratio of at least five toone, and wherein the height of the first dispensing orifices is at leastthree times larger than the height of the second dispensing orifices.

In a forty-fourth embodiment, the present disclosure provides theextrusion die of the forty-third embodiment, wherein the fluidpassageways are provided by a plurality of sequences of shims, whereineach sequence comprises at least one first shim that provides a fluidpassageway.

In a forty-fifth embodiment, the present disclosure provides theextrusion die of the forty-third embodiment, wherein the extrusion diecomprises at least a first and second cavity, first fluid passagewaysbetween the first cavity and the first dispensing orifices, and secondfluid passageways between the second cavity and the second dispensingorifices.

In a forty-sixth embodiment, the present disclosure provides theextrusion die of the forty-fifth embodiment, wherein the fluidpassageways are provided by a plurality of sequences of shims, whereineach sequence comprises at least one first shim that provides the firstfluid passageway, and at least one second shim that provides the secondfluid passageway.

In a forty-seventh embodiment, the present disclosure provides theextrusion die of any one of the forty-third to forty-sixth embodiments,wherein at least the first dispensing orifices are defined by an arrayof first vestibules, the die further comprising a third cavity, a firstfluid passageway between the first cavity and one of the firstvestibules, a third passageway extending from the third cavity to thesame vestibule, such that the area where the third fluid passagewayenters the first vestibule is below the area where the first fluidpassageway enters the first vestibule.

In a forty-eighth embodiment, the present disclosure provides theextrusion die of the forty-seventh embodiment, wherein the fluidpassageways are provided by a plurality of sequences of shims, whereineach sequence comprises at least one first shim that provides the firstfluid passageway, and at least one third shim that provides the thirdfluid passageway.

In a forty-ninth embodiment, the present disclosure provides theextrusion die of any one of the forty-third to forty-eighth embodiments,wherein the second dispensing orifices are vertically aligned closer tothe bottom edges than the top edges of the first dispensing orifices.

In a fiftieth embodiment, the present disclosure provides the extrusiondie of any one of the forty-third to forty-eighth embodiments, whereinthe first and second dispensing orifices are vertically centered.

In a fifty-first embodiment, the present disclosure provides theextrusion die of any one of the forty-third to forty-eighth embodiments,wherein the second dispensing orifices are vertically aligned, andwherein a first portion of the first dispensing orifices have theirbottom edges closer to the second dispensing orifices than their topedges, and wherein a second portion of the first dispensing orificeshave their top edges closer to the second dispensing orifices than theirbottom edges.

In a fifty-second embodiment, the present disclosure provides theextrusion die of any one of the forty-third to fifty-first embodiments,wherein the height-to-width aspect ratio of at least some of the firstdispensing orifices is at least 11 to 1.

In a fifty-third embodiment, the present disclosure provides theextrusion die of any one of the forty-third to fifty-second embodiments,wherein the first dispensing orifices do not have a uniform height.

In a fifty-fourth embodiment, the present disclosure provides a methodof making a polymeric netting, the method comprising:

providing the extrusion die of any one of the forty-third tofifty-second embodiments; and

dispensing polymeric ribbons from the first dispensing orifices at afirst speed while simultaneously dispensing polymeric strands from thesecond dispensing orifices at a second speed to provide the polymericnetting, wherein the first speed is at least twice the second speed, orwherein the second speed is at least twice the first speed.

In a fifty-fifth embodiment, the present disclosure provides a method ofmaking a polymeric netting, the method comprising:

providing an extrusion die comprising at least one cavity, a dispensingsurface, and fluid passageways between the at least one cavity and thedispensing surface, wherein the dispensing surface has an array of firstdispensing orifices separated by an array of second dispensing orifices,wherein the first and second dispensing orifices each have a top edge, abottom edge, a height that is the distance between the top edge and thebottom edge, and a width, wherein the first dispensing orifices eachhave a height-to-width aspect ratio of at least five to one, and whereinthe height of the first dispensing orifices is at least two times largerthan the height of the second dispensing orifices;

dispensing polymeric ribbons from the first dispensing orifices at afirst speed while simultaneously dispensing polymeric strands from thesecond dispensing orifices at a second speed to provide the polymericnetting, wherein the second speed is at least twice the first speed.

In a fifty-sixth embodiment, the present disclosure provides the methodof the fifty-fifth embodiment, wherein the fluid passageways areprovided by a plurality of sequences of shims, wherein each sequencecomprises at least one first shim that provides a fluid passageway.

In a fifty-seventh embodiment, the present disclosure provides themethod of the fifty-fifth embodiment, wherein the extrusion diecomprises at least a first and second cavity, first fluid passagewaysbetween the first cavity and the first dispensing orifices, and secondfluid passageways between the second cavity and the second dispensingorifices.

In a fifty-eighth embodiment, the present disclosure provides the methodof the fifty-seventh embodiment, wherein the fluid passageways areprovided by a plurality of sequences of shims, wherein each sequencecomprises at least one first shim that provides the first fluidpassageway, and at least one second shim that provides the second fluidpassageway.

In a fifty-ninth embodiment, the present disclosure provides the methodof the fifty-fifth or fifty-seventh embodiment, wherein at least thefirst dispensing orifices are defined by an array of first vestibules,the die further comprising a third cavity, a first fluid passagewaybetween the first cavity and one of the first vestibules, a thirdpassageway extending from the third cavity to the same vestibule, suchthat the area where the third fluid passageway enters the firstvestibule is above or below the area where the first fluid passagewayenters the first vestibule.

In a sixtieth embodiment, the present disclosure provides the method ofthe fifty-ninth embodiment, wherein the fluid passageways are providedby a plurality of sequences of shims, wherein each sequence comprises atleast one first shim that provides the first fluid passageway, and atleast one third shim that provides the third fluid passageway.

In a sixty-first embodiment, the present disclosure provides the methodof any one of the fifty-fifth to sixtieth embodiments, wherein thepolymeric ribbons are substantially straight.

In a sixty-second embodiment, the present disclosure provides the methodof any one of the fifty-fifth to sixty-first embodiments, wherein thepolymeric strands oscillate to at least partially alternately bond totwo adjacent polymeric ribbons.

In a sixty-third embodiment, the present disclosure provides the methodof any one of the fifty-fifth to sixty-second embodiments, wherein thepolymeric strands and polymeric ribbons do not intersect each other.

In a sixty-fourth embodiment, the present disclosure provides the methodof any one of the fifty-fifth to sixty-third embodiments, wherein theheight-to-width aspect ratio of at least some of the first dispensingorifices is at least 11 to 1.

In a sixty-fifth embodiment, the present disclosure provides the methodof any one of the fifty-fifth to sixty-fourth embodiments, wherein theheight of at least some of the polymeric ribbons is greater than 750micrometers.

In a sixty-sixth embodiment, the present disclosure provides the methodof any one of the fifty-fifth to sixty-fourth embodiments, wherein theheight of at least some of the polymeric ribbons is less than 750micrometers.

In a sixty-seventh embodiment, the present disclosure provides themethod of any one of the fifty-fifth to sixty-sixth embodiments, whereinat least some of the polymeric ribbons have a different color than atleast some of the polymeric strands.

In a sixty-eighth embodiment, the present disclosure provides the methodof any one of the fifty-fifth to sixty-seventh embodiments, wherein atleast some of the polymeric ribbons have a different polymericcomposition than at least some of the polymeric strands.

In a sixty-ninth embodiment, the present disclosure provides the methodof any one of the fifty-fifth to sixty-eighth embodiments, wherein thepolymeric ribbons are elastic, the polymeric strands are elastic, orboth the polymeric ribbons and the polymeric strands are elastic.

In a seventieth embodiment, the present disclosure provides the methodof any one of the fifty-fifth to sixty-ninth embodiments, wherein thesecond dispensing orifices are vertically aligned closer to the bottomedges than the top edges of the first dispensing orifices.

In a seventy-first embodiment, the present disclosure provides themethod any one of the fifty-fifth to seventieth embodiments, wherein thepolymeric ribbons each have a center line bisecting the major surfaceand first and second edges symmetrically disposed on opposite sides ofthe center line, wherein the major surface is intermittently bonded toonly one polymeric strand at a location between the center line and thefirst edge.

In a seventy-second embodiment, the present disclosure provides themethod of the seventieth or seventy-first embodiment, wherein thepolymeric ribbons each have a center line bisecting the major surfaceand first and second edges symmetrically disposed on opposite sides ofthe center line, wherein the polymeric netting has first and secondopposing major surfaces transverse to the major surfaces of thepolymeric ribbons, wherein the first major surface of the polymericnetting comprises the first edges of the polymeric ribbons, and whereinthe second major surface comprises the second edges of the polymericribbons and portions of at least some of the polymeric strands.

In a seventy-third embodiment, the present disclosure provides themethod of any one of the fifty-fifth to sixty-ninth embodiments, whereinthe first and second dispensing orifices are vertically centered.

In a seventy-fourth embodiment, the present disclosure provides themethod of any one of the fifty-fifth to sixty-ninth and seventy-thirdembodiments, wherein the polymeric ribbons each have a center linebisecting the major surface, and wherein the major surface isintermittently bonded to only one polymeric strand at a locationincluding the center line.

In a seventy-fifth embodiment, the present disclosure provides themethod of the seventy-third or seventy-fourth embodiment, wherein thepolymeric ribbons and polymeric strands are vertically centered.

In a seventy-sixth embodiment, the present disclosure provides themethod of any one of the fifty-fifth to sixty-ninth and seventy-third toseventy-fifth embodiments, wherein the polymeric ribbons each have acenter line bisecting the major surface and first and second edgessymmetrically disposed on opposite sides of the center line, wherein thepolymeric netting has first and second opposing major surfacestransverse to the major surfaces of the polymeric ribbons, wherein thefirst major surface of the polymeric netting comprises the first edgesof the polymeric ribbons, and wherein the second major surface comprisesthe second edges of the polymeric ribbons, and wherein neither the firstnor second major surfaces comprise a portion of the polymeric strands.

In a seventy-eighth embodiment, the present disclosure provides themethod of any one of the fifty-fifth to sixty-ninth embodiments, whereinthe second dispensing orifices are vertically aligned, and wherein afirst portion of the first dispensing orifices have their bottom edgescloser to the second dispensing orifices than their top edges, andwherein a second portion of the first dispensing orifices have their topedges closer to the second dispensing orifices than their bottom edges.

In a seventy-ninth embodiment, the present disclosure provides themethod of the seventy-eighth embodiment, wherein the first dispensingorifices alternate between top edges substantially aligned with the topedges of the second dispensing orifices and bottom edges substantiallyaligned with the bottom edges of the second dispensing orifices.

In an eightieth embodiment, the present disclosure provides the methodof any one of the fifty-fifth to sixty-ninth, seventy-eighth orseventy-ninth embodiments, wherein the polymeric ribbons each have acenter line bisecting the major surface and first and second edgessymmetrically disposed on opposite sides of the center line, wherein themajor surface of a first portion of the polymeric ribbons is bonded toonly one polymeric strand at a location between the center line and thefirst edge and the major surface of a second portion of the polymericribbons is bonded to only one polymeric strand at a location between thecenter line at the second edge.

In an eighty-first embodiment, the present disclosure provides themethod of any one of the fifty-fifth to sixty-ninth and seventy-eighthto eightieth embodiments, wherein the polymeric ribbons each have acenter line bisecting the major surface and first and second edgessymmetrically disposed on opposite sides of the center line, wherein thepolymeric netting has first and second opposing major surfacestransverse to the major surfaces of the polymeric ribbons, wherein thefirst major surface of the polymeric netting comprises the first edgesof a first portion of the polymeric ribbons, wherein the second majorsurface comprises the second edges of the polymeric ribbons, wherein thefirst portion of the polymeric ribbons does not extend to the secondmajor surface, and wherein the second portion of the polymeric ribbonsdoes not extend to the first major surface.

In an eighty-second embodiment, the present disclosure provides thepolymeric netting of any one of the first to nineteenth embodimentsjoined to a carrier.

In an eighty-third embodiment, the present disclosure provides thepolymeric netting of any one of the first to nineteenth embodiments foruse as an elastic wrap.

In order that this disclosure can be more fully understood, thefollowing examples are set forth. It should be understood that theseexamples are for illustrative purposes only, and are not to be construedas limiting this disclosure in any manner. All parts and percentages areby weight unless otherwise indicated.

EXAMPLES Example 1

A co-extrusion die as generally depicted in FIGS. 22 and 23 andassembled with a multi shim repeating pattern of extrusion orifices asgenerally illustrated in FIGS. 12A and 12B was prepared. The thicknessof the shims in the repeat sequence was 4 mils (0.102 mm). These shimswere formed from stainless steel, with perforations cut by a wireelectron discharge machining. Referring to FIG. 11, the height ofdispensing orifices 356 of shims 300 were cut to 100 mils (2.54 mm).Referring to FIG. 9, the height of the dispensing orifice 156 of shims100 were cut to 30 mils (0.762 mm). The shims were stacked in arepeating sequence 100, 100, 200, 200, 300, 300, 200, 200. As assembledthe width of the dispensing openings 1001 and 1003 were each 0.203 mm,and the land spacings between openings were 0.203 mm. The extrusionorifices were aligned in a collinear, alternating arrangement, andresulting dispensing surface was as shown in FIG. 12B. The total widthof the shim setup was about 13 cm. (5 inches)

The inlet fittings on the two end blocks were each connected to threeconventional single-screw extruders. Each extruder feeding cavities 1012a and 1012 c were loaded with polypropylene homopolymer (obtained underthe trade designation “1024PP” from Exxon Mobil, Irving, Tex.).

The flow rate of the polymer exiting openings 1003 was 1.7 kg/hr, andflow rate of the polymer exiting openings 1001 was 1.9 kg/hr. The meltwas extruded vertically into an extrusion quench takeaway. The quenchtakeaway speed was 5.2 m/min, and the melt drop distance was 3 cm. Theextrusion temperature was 218° C. The polymer exiting openings 1003 wasoscillating. The quench roll was a smooth temperature controlled chromeplated 20-cm diameter steel roll. The quench temperature, which was 10°C., was controlled with internal water flow. The web path wrapped 180degrees around the chrome steel roll and then to a windup roll.

A photograph of the polymeric netting obtained is shown in FIG. 30.Using an optical microscope at 30× magnification, the polymeric strandwidth and height were determined to be 80 micrometers and 373micrometers respectively, and the polymeric ribbon width and height weredetermined to be 80 micrometers and 600 micrometers, respectively. Thebasis weight of the polymeric netting was measured by weighing three 2inch by 10 inch (5.1 cm by 25.4 cm) pieces of the netting with ananalytical balance and averaging the values. The basis weight of thepolymeric netting was found to be 125 g/m², and its overall caliper was600 micrometers.

The top sheet was removed from a 270 mm by 90 mm pad obtained from FirstQuality Retail Services, Macon, Ga., under the trade designation“OPTIONS ULTRA THINS”, and the top sheet was replaced with a piece ofthe polymeric netting described above. The piece of the polymericnetting had dimensions of approximately 260 mm by 90 mm. The polymericnetting was placed on top of the acquisition/distribution layer withoutadhesive.

Example 1b

A piece of the polymeric netting (approximately 260 mm by 90 mm) made asdescribed in Example 1 was soaked in a solution made from 90 grams ofwater and 10 grams of surfactant obtained from Dow Chemical Company,Midland, Mich., under the trade designation “TRITON X-100”. Aftercompletely submerging the polymeric netting, it was immediately removedfrom the solution, and the excess liquid was allowed to drip off. Thesample was placed on an aluminum tray and dried for two hours at 50° C.in a batch oven. The top sheet was removed from a 270 mm by 90 mm padobtained from First Quality Retail Services under the trade designation“OPTIONS ULTRA THINS”, and the top sheet was replaced with the soakedand dried polymeric netting. The polymeric netting was placed on top ofthe acquisition/distribution layer without adhesive.

Example 1c

The top sheet was removed from a 270 mm by 90 mm pad obtained from FirstQuality Retail Services under the trade designation “OPTIONS ULTRATHINS”, and the acquisition/distribution was removed and replaced with apiece of the polymeric netting made as described in Example 1. The pieceof the polymeric netting had dimensions of approximately 165 mm by 50mm. The polymeric netting was placed on top of the absorbent withoutadhesive, and the original topsheet was positioned on top of thepolymeric netting without adhesive.

Example 2

A co-extrusion die as generally depicted in FIGS. 22 and 23 andassembled with a multi shim repeating pattern of extrusion orifices asgenerally illustrated in FIGS. 15A and 15B, with the modification thatone shim 500 was used instead of two, was prepared. The thickness of theshims in the repeat sequence was 4 mils (0.102 mm) for shims 400 and200. The thickness of the shims in the repeat sequence was 8 mils (0.203mm) for shims 500. These shims were formed from stainless steel, withperforations cut by a wire electron discharge machining. Referring toFIG. 14, the height of the dispensing openings 556 of shims 500 were cutto 100 mils (2.54 mm). Referring to FIG. 13, the height of thedispensing openings 456 of shims 400 were cut to 20 mils (0.508 mm). Theshims were stacked in a repeating sequence 400, 400, 400, 400, 200, 200,200, 200, 500, 200, 200, 200, 200. As assembled the width of thedispensing openings 1103 and 1101 were 0.406 mm and 0.203 mm,respectively, and the land spacings between openings were 0.406 mm. Theextrusion orifices were aligned in a collinear, alternating arrangement,and resulting dispensing surface was as shown in FIG. 15B. The totalwidth of the shim setup was about 15 cm.

The inlet fittings on the two end blocks were each connected to threeconventional single-screw extruders. Each extruder feeding cavities 1112a and 1112 b were loaded with styrene-ethylene/butylene-styrene blockcopolymer elastomer (obtained under the trade designation “MD6751” fromKraton, Belpre, Ohio) dry blended with 3% yellow and green colorantmasterbatch, respectively (yellow colorant obtained under the tradedesignation “PANTONE YELLOW” from Americhem, Cuyahoga Falls, Ohio, greenobtained under the trade designation “PAN3385C MINT GREEN” fromClariant, Minneapolis, Minn.).

The flow rate of the yellow polymer exiting openings 1103 was 3.74kg/hr, and flow rate of the green polymer exiting openings 1101 was 2.95kg/hr. The melt was extruded vertically into an extrusion quenchtakeaway. The quench takeaway speed was 1.54 m/min, and the melt dropdistance was 4 cm. The extrusion temperature was 232° C. The polymerexiting openings 1103 was oscillating. The quench roll was a smooth,temperature-controlled chrome plated 20-cm diameter steel roll. Thequench temperature, which was 10° C., was controlled with internal waterflow. The web was further cooled on the quench roll with compressed airflow through four 2.5-inch (6.35 cm) Loc-Line® Swivel Nozzle 75(Lockwood Products, INC, Lake Oswego, Oreg.). The web path wrapped 180degrees around the chrome steel roll and then to a windup roll.

Photographs of the polymeric netting obtained are shown in FIGS. 31A and31B. Using an optical microscope at 30× magnification, the polymericstrand width and height were determined to be 426 micrometers and 773micrometers, respectively, and the polymeric ribbon width and heightwere determined to be 229 micrometers and 2066 micrometers,respectively. The basis weight of the polymeric netting was measured asdescribed in Example 1 and found to be 568 g/m², and its overall caliperwas 2066 micrometers.

Example 3

A co-extrusion die as generally depicted in FIGS. 22 and 23 andassembled with a multi shim repeating pattern of extrusion orifices asgenerally illustrated in FIGS. 21A and 21B, with the modification thatone shim 500 was used instead of two, was prepared. The thickness of theshims in the repeat sequence was 4 mils (0.102 mm) for shims 800 and200. The thickness of the shims in the repeat sequence was 8 mils (0.203mm) for shims 500. The thickness of the shims in the repeat sequence was2 mils (0.051 mm) for shims 900. These shims were formed from stainlesssteel, with perforations cut by a wire electron discharge machining.Referring to FIG. 14, the height of the dispensing openings 556 of shims500 were cut to 100 mils (2.54 mm). Referring to FIG. 19, the height ofthe dispensing openings 856 of shims 800 were cut to 15 mils (0.381 mm).The shims were stacked in a repeating sequence 800, 800, 800, 200, 200,200, 900, 500, 900, 200, 200, 200. As assembled the width of thedispensing openings 1303 and 1301 were 0.305 mm and 0.203 mm,respectively, and the land spacings between openings were 0.305 mm. Theextrusion orifices were aligned in a collinear, alternating arrangement,and resulting dispensing surface was as shown in FIG. 21B. The totalwidth of the shim setup was about 10 cm.

The inlet fittings on the two end blocks were each connected to threeconventional single-screw extruders. Each extruder feeding cavities 1312a and 1312 b were loaded with styrene-ethylene/butylene-styrene blockcopolymer elastomer (obtained under the trade designation “MD6752” fromKraton, Belpre, Ohio) dry blended with 3% pink or black colorantmasterbatch, respectively, (pink and black obtained under the tradedesignation “PAN813C NEON PINK” and “PANTONE BLACK C” from Clariant,Minneapolis, Minn.).

The flow rate of the pink polymer exiting openings 1303 was 2.04 kg/hr,and flow rate of the black polymer exiting openings 1301 was 3.61 kg/hr.The melt was extruded vertically into an extrusion quench takeaway. Thequench takeaway speed was 1.67 m/min, and the melt drop distance was 4cm. The extrusion temperature was 232° C. The polymer exiting openings1303 was oscillating. The quench roll was a smooth,temperature-controlled chrome plated 20-cm diameter steel roll. Thequench temperature, which was 10° C., was controlled with internal waterflow. The web was further cooled on the quench roll with compressed airflow through four 2.5-inch (6.35 cm) Loc-Line® Swivel Nozzle 75(Lockwood Products, INC, Lake Oswego, Oreg.). The web path wrapped 180degrees around the chrome steel roll and then to a windup roll.

Photographs of the polymeric netting obtained are shown in FIGS. 32A and32B. Using an optical microscope at 30× magnification, the polymericstrand width and height were determined to be 476 micrometers and 614micrometers, respectively, and the polymeric ribbon width and heightwere determined to be 189 micrometers and 2365 micrometers,respectively. The basis weight of the polymeric netting was measured asdescribed in Example 1 and found to be 649 g/m², and its overall caliperwas 2365 micrometers.

Example 4

A co-extrusion die as generally depicted in FIGS. 22 and 23 andassembled with a multi shim repeating pattern of extrusion orifices asgenerally illustrated in FIGS. 18A and 18B was prepared. The thicknessof the shims in the repeat sequence was 4 mils (0.102 mm) for shims 700,200, 600, and 300. These shims were formed from stainless steel, withperforations cut by a wire electron discharge machining. Referring toFIGS. 11 and 17, the heights of the dispensing openings 356 and 756 ofshims 300 and 700 were both cut to 100 mils (2.54 mm). The height of thedispensing opening 656 of shims 600 were both cut to 30 mils (0.765 mm).The shims were stacked in a repeating sequence 700, 700, 200, 200, 600,600, 200, 200, 300, 300, 200, 200, 600, 600, 200, 200. As assembled thewidth of the dispensing openings 1203 and 1201 were each 0.203 mm, andthe land spacings between openings were 0.203 mm. The extrusion orificeswere aligned in a collinear, alternating arrangement, and resultingdispensing surface was as shown in FIGS. 18A and 18B. The total width ofthe shim setup was about 12.5 cm.

The inlet fittings on the two end blocks were each connected to threeconventional single-screw extruders. Each extruder feeding cavities 1212a, 1212 b and 1212 c were loaded with styrene-ethylene/butylene-styreneblock copolymer elastomer (obtained under the trade designation “MD6751”from Kraton, Belpre, Ohio) dry blended with 3% pink, yellow, and purplecolorant masterbatch, respectively, (yellow colorant obtained under thetrade designation “YELLOW 116” from Americhem, Cuyahoga Falls, Ohio,neon pink and purple obtained under the trade designation “PAN813C NEONPINK” and “PAN266C PURPLE” from Clariant, Minneapolis, Minn.).

The flow rate of the pink polymer exiting openings 1201 was 2.0 kg/hr,and the flow rate of the yellow polymer exiting openings 1203 was 3.08kg/hr, and the flow rate of the purple polymer exiting openings 1201 was1.36 kg/hr. The melt was extruded vertically into an extrusion quenchtakeaway. The quench takeaway speed was 1.67 m/min, and the melt dropdistance was 4 cm. The extrusion temperature was 232° C. The polymerexiting openings 1203 was oscillating. The quench roll was a smooth,temperature-controlled chrome plated 20-cm diameter steel roll. Thequench temperature, which was 10° C., was controlled with internal waterflow. The web was further cooled on the quench roll with compressed airflow through four 2.5-inch (6.35 cm) Loc-Line® Swivel Nozzle 75(Lockwood Products, INC, Lake Oswego, Oreg.). The web path wrapped 180degrees around the chrome steel roll and then to a windup roll.

Photographs of the polymeric netting obtained are shown in FIGS. 33A and33B. Using an optical microscope at 30× magnification, the polymericstrand width and height were determined to be 306 micrometers and 747micrometers, respectively, the pink polymeric ribbon width and heightwere determined to be 204 micrometers and 1736 micrometers,respectively, and the purple polymeric ribbon width and height weredetermined to be 200 micrometers and 1782 micrometers, respectively. Thebasis weight of the polymeric netting was measured as described inExample 1 and found to be 680 g/m², and its overall caliper was 3.03 mm.

Example 4a

The top sheet was removed from a 270 mm by 90 mm pad obtained from FirstQuality Retail Services under the trade designation “OPTIONS ULTRATHINS”, and the top sheet was replaced with a piece of the polymericnetting prepared in Example 4. The piece of the polymeric netting haddimensions of approximately 260 mm by 90 mm. The polymeric netting wasplaced on top of the acquisition/distribution layer without adhesive.

Example 4b

A piece of the polymeric netting made as described in Example 4(approximately 260 mm by 90 mm) was soaked in a solution made from 90grams of water and 10 grams of surfactant obtained from Dow ChemicalCompany under the trade designation “TRITON X-100”, removed from thesolution, and dried as described in Example 1b. The top sheet wasremoved from a 270 mm by 90 mm pad obtained from First Quality RetailServices under the trade designation “OPTIONS ULTRA THINS”, and the topsheet was replaced with the soaked and dried polymeric netting. Thepolymeric netting was placed on top of the acquisition/distributionlayer without adhesive.

Example 4c

The top sheet was removed from a 270 mm by 90 mm pad obtained from FirstQuality Retail Services under the trade designation “OPTIONS ULTRATHINS”, and the acquisition/distribution was removed and replaced with apiece of the polymeric netting made as described in Example 4. The pieceof the polymeric netting had dimensions of approximately 165 mm by 50mm. The polymeric netting was placed on top of the absorbent withoutadhesive, and the original topsheet was positioned on top of thepolymeric netting without adhesive.

Example 5

Example 5 was prepared using the method described above for Example 2with the following modifications. The total width of the shim setup wasabout 13 cm. Each extruder feeding cavities 1112 a and 1112 b wereloaded with styrene-ethylene/butylene-styrene block copolymer elastomer(obtained under the trade designation “G1645” from Kraton). No colorantwas added. The extrusion temperature was 254° C. The quench takeawayspeed was 1.52 m/min, and the melt drop distance was 3 cm. Using anoptical microscope at 30× magnification, the polymeric strand width andheight were determined to be 450 micrometers and 700 micrometers,respectively, and the polymeric ribbon width and height were determinedto be 200 micrometers and 2400 micrometers, respectively. The basisweight of the polymeric netting was measured as described in Example 1and found to be 641 g/m², and its overall caliper was 2400 micrometers.

Example 6

Example 6 was prepared using the method described above for Example 1with the following modifications. Shim 400 shown in FIG. 13 was usedinstead of shim 100 shown in FIG. 9. The height of the dispensingopenings 456 of shims 400 were cut to 20 mils (0.508 mm). The shims werestacked in a repeating sequence 400, 400, 200, 200, 300, 300, 200, 200.The total width of the shim setup was about 10 cm.

The inlet fittings on the two end blocks were each connected to threeconventional single-screw extruders. Each extruder feeding cavities 1012a and 1012 c were loaded with styrene-ethylene/butylene-styrene blockcopolymer elastomer (obtained under the trade designation “1130120” fromKraton) dry blended with 2 wt. % deep green and 3 wt. % green colorantmasterbatches, respectively (deep green colorant was obtained under thetrade designation “DEEP SATURATED GREEN”, and green colorant wasobtained under the trade designation “PAN802C GREEN”, both fromClariant).

The flow rate of the polymer exiting openings 1003 in an oscillatingfashion was 1.3 kg/hr, and flow rate of the polymer exiting openings1001 was 2.25 kg/hr. The quench takeaway speed was 1.5 m/min, and themelt drop distance was 4 cm. The extrusion temperature was 232° C.

Photographs of the polymeric netting obtained are shown in FIGS. 34A and34B. Using an optical microscope at 30× magnification, the polymericstrand width and height were determined to be 350 micrometers and 360micrometers respectively, and the polymeric ribbon width and height weredetermined to be 110 micrometers and 925 micrometers, respectively. Thebasis weight of the polymeric netting was measured as described inExample 1 and found to be 240 g/m², and its overall caliper was 925micrometers.

Example 6a

The top sheet was removed from a 270 mm by 90 mm pad obtained from FirstQuality Retail Services under the trade designation “OPTIONS ULTRATHINS”, and the top sheet was replaced with a piece of the polymericnetting prepared in Example 6. The piece of the polymeric netting haddimensions of approximately 260 mm by 90 mm. The polymeric netting wasplaced on top of the acquisition/distribution layer without adhesive.

Example 6b

A piece of the polymeric netting made as described in Example 6(approximately 260 mm by 90 mm) was soaked in a solution made from 90grams of water and 10 grams of surfactant obtained from Dow ChemicalCompany under the trade designation “TRITON X-100”, removed from thesolution, and dried as described in Example 1b. The top sheet wasremoved from a 270 mm by 90 mm pad obtained from First Quality RetailServices under the trade designation “OPTIONS ULTRA THINS”, and the topsheet was replaced with the soaked and dried polymeric netting. Thepolymeric netting was placed on top of the acquisition/distributionlayer without adhesive.

Example 6c

The top sheet was removed from a 270 mm by 90 mm pad obtained from FirstQuality Retail Services under the trade designation “OPTIONS ULTRATHINS”, and the acquisition/distribution was removed and replaced with apiece of the polymeric netting made as described in Example 6. The pieceof the polymeric netting had dimensions of approximately 165 mm by 50mm. The polymeric netting was placed on top of the absorbent withoutadhesive, and the original topsheet was positioned on top of thepolymeric netting without adhesive.

Comparative Example A

Comparative Example A was an unmodified 270 mm by 90 mm pad obtainedfrom First Quality Retail Services under the trade designation “OPTIONSULTRA THINS”.

Comparative Example B

Comparative Example B was a 270 mm by 90 mm pad obtained from FirstQuality Retail Services under the trade designation “OPTIONS ULTRATHINS” in which the topsheet had been removed and replaced.

Test Methods Strike-Through Time:

The strike through time was measured using a test jig shown in FIG. 19.The jig was made of a poly(methyl methacrylate) sheet and had adimension of 203 mm by 203 mm by 5 mm. A glass funnel with 15-mmdiameter circular opening at the bottom was fit into a complimentaryopening in the poly(methyl methacrylate) sheet, and the funnel wassealed into the opening with wax. Comparative Examples A and B and theExamples were each individually placed between the test jig and apoly(methyl methacrylate) sheet having a dimension of 203 mm by 203 mmby 5 mm having no opening. The opening in the test jig was placedapproximately over the center of the pad. Four 250-gram weights wereplaced on top of the poly(methyl methacrylate) sheet, one in each of thefour corners, which provided a 572 Pa (0.083 psi) force onto the pad.The bottom of the funnel was in contact with the pad. A volume of 20 mLof 0.9% NaCl aqueous solution including a small amount of red dyeobtained from Aldrich Chemical Company, Milwaukee, Wis., under the tradedesignation “DIRECT RED 81” was poured through the funnel. Thestrike-through time was measured with a stopwatch in seconds from thetime the solution was poured into the funnel and the time the funnel wastotally empty. One sample was tested for each Example and ComparativeExample.

Rewet:

The test jig was removed from the pad at the end of the Strike-throughTime evaluation, and the pad was allowed to stand for five minutes afterthe solution was applied. Ten pieces of pre-weighed VWR filter paper#110 (11 cm circle) were then applied on the top of the pad in thecenter in a stack, and a 152 mm by 78 mm weight (1967.2 grams) wasplaced on top of the filter paper for three minutes. The weight wasremoved, and the pieces of filter paper were reweighed. The rewet ingrams was recorded as the weight gain on the pieces of filter paper.

Fluid Distribution:

After the weight was removed from the sample in the Rewet evaluation,the distance the distance that the solution traveled along the padlengthwise and widthwise was measured using a ruler.

The Strike-Through Time, Rewet, and Fluid Distribution length and widthfor each of Comparative Examples A and B and Examples 1, 1b, 1c, 4a, 4b,4c, 6a, 6b, and 6c are reported in Table 1, below.

TABLE 1 Fluid Fluid Strike-Through Rewet Distribution DistributionExample Time (seconds) (grams) Length (mm) Width (mm) Comp. Ex. A 7.80.046 115 65 Comp. Ex. B 5.3 0.702 100 70 Example 1 5.3 0.024 120 65Example 1b 3.5 0.034 130 65 Example 6a 4.5 0.024 130 65 Example 6b 4.60.022 135 65 Example 4a 2.3 1.655^(a) 150 65 Example 4b 1.6 0.163 180 50Example 1c 7.4 0.369^(b) 110 65 Example 6c 6.3 0.564^(b) 150 65 Example4c 2.4 0.708^(b) 190 50 ^(a)The liquid did not go through the netting,so the rewet value is higher. ^(b)It is believed that the disruption ofthe pad created air gaps and SAP contamination on the topsheet to causehigher rewet values.

Foreseeable modifications and alterations of this disclosure will beapparent to those skilled in the art without departing from the scopeand spirit of this invention. This invention should not be restricted tothe embodiments that are set forth in this application for illustrativepurposes.

1. A polymeric netting comprising polymeric ribbons and polymericstrands, each of the polymeric ribbons and strands having a length andwidth, wherein the length is the longest dimension and the width is theshortest dimension, wherein the polymeric ribbons have a height-to-widthaspect ratio of at least five to one, a major surface that isintermittently bonded to only one polymeric strand, and a height that isat least two times greater than a height of the one polymeric strand. 2.The polymeric netting of claim 1, wherein the polymeric ribbons eachhave a center line bisecting the major surface and first and secondedges symmetrically disposed on opposite sides of the center line,wherein the major surface is intermittently bonded to only one polymericstrand at a location closer to the first edge than the second edge. 3.The polymeric netting of claim 1, wherein the polymeric ribbons eachhave a center line bisecting the major surface, and wherein the majorsurface is intermittently bonded to only one polymeric strand at alocation including the center line.
 4. The polymeric netting of claim 1,wherein the polymeric ribbons each have a center line bisecting themajor surface and first and second edges symmetrically disposed onopposite sides of the center line, wherein the first edges of thepolymeric ribbons comprise a different composition than the second edgesof the polymeric ribbons.
 5. The polymeric netting of claim 1, whereinthe polymeric ribbons each have a center line bisecting the majorsurface and first and second edges symmetrically disposed on oppositesides of the center line, wherein the major surface of a first group ofthe polymeric ribbons is bonded to only one polymeric strand at alocation between the center line and the first edge and the majorsurface of a second group of the polymeric ribbons is bonded to only onepolymeric strand at a location between the center line at the secondedge.
 6. The polymeric netting of claim 1, wherein the polymeric ribbonsand polymeric strands alternate in at least a portion of the polymericnetting.
 7. The polymeric netting of claim 1, wherein theheight-to-width aspect ratio of at least some of the polymeric ribbonsis greater than 7 to
 1. 8. The polymeric netting of claim 1, wherein atleast some of the polymeric ribbons have a different color than at leastsome of the polymeric strands.
 9. The polymeric netting of claim 1,wherein the polymeric ribbons are elastic, the polymeric strands areelastic, or both the polymeric ribbons and the polymeric strands areelastic.
 10. An absorbent article comprising a polymeric netting, aliquid impermeable backsheet, and an absorbent core, wherein thepolymeric netting comprises polymeric ribbons and polymeric strands,each of the polymeric ribbons and strands having a length and width,wherein the length is the longest dimension and the width is theshortest dimension, wherein the polymeric ribbons have a height-to-widthaspect ratio of at least three to one, a major surface that isintermittently bonded to only one polymeric strand, and a height that isgreater than a height of the one polymeric strand, and wherein theabsorbent core is between the polymeric netting and the backsheet,wherein the polymeric netting is between the absorbent core and thebacksheet, or wherein the polymeric netting is within the absorbentcore.
 11. An extrusion die comprising at least one cavity, a dispensingsurface, and fluid passageways between the at least one cavity and thedispensing surface, wherein the dispensing surface has an array of firstdispensing orifices separated by an array of second dispensing orifices,wherein the first dispensing orifices, second dispensing orifices, andany other dispensing orifices are arranged in a single row across thedispensing surface, wherein the first and second dispensing orificeseach have a height and a width, wherein the first dispensing orificeseach have a height-to-width aspect ratio of at least five to one, andwherein the height of the first dispensing orifices is at least threetimes larger than the height of the second dispensing orifices.
 12. Amethod of making the polymeric netting of claim 1, the methodcomprising: providing an extrusion die comprising at least one cavity, adispensing surface, and fluid passageways between the at least onecavity and the dispensing surface, wherein the dispensing surface has anarray of first dispensing orifices separated by an array of seconddispensing orifices, wherein the first and second dispensing orificeseach have a height and a width, wherein the first dispensing orificeseach have a height-to-width aspect ratio of at least five to one, andwherein the height of the first dispensing orifices is at least twotimes larger than the height of the second dispensing orifices;dispensing polymeric ribbons from the first dispensing orifices at afirst speed while simultaneously dispensing polymeric strands from thesecond dispensing orifices at a second speed to provide the polymericnetting, wherein the second speed is at least twice the first speed. 13.The method of claim 12, wherein the polymeric ribbons are substantiallystraight.
 14. The method of claim 12, wherein the height-to-width aspectratio of at least some of the first dispensing orifices is at least 11to
 1. 15. The method of claim 12, wherein the extrusion die comprises atleast a first and second cavity, first fluid passageways between thefirst cavity and the first dispensing orifices, and second fluidpassageways between the second cavity and the second dispensingorifices.
 16. The absorbent article of claim 10, wherein the polymericribbons each have a center line bisecting the major surface and firstand second edges symmetrically disposed on opposite sides of the centerline, wherein the major surface is intermittently bonded to only onepolymeric strand at a location closer to the first edge than the secondedge.
 17. The absorbent article of claim 10, wherein the polymericribbons each have a center line bisecting the major surface, and whereinthe major surface is intermittently bonded to only one polymeric strandat a location including the center line.
 18. The absorbent article ofclaim 10, wherein the polymeric ribbons each have a center linebisecting the major surface and first and second edges symmetricallydisposed on opposite sides of the center line, wherein the first edgesof the polymeric ribbons comprise a different composition than thesecond edges of the polymeric ribbons.
 19. The absorbent article ofclaim 10, wherein the polymeric ribbons each have a center linebisecting the major surface and first and second edges symmetricallydisposed on opposite sides of the center line, wherein the major surfaceof a first group of the polymeric ribbons is bonded to only onepolymeric strand at a location between the center line and the firstedge and the major surface of a second group of the polymeric ribbons isbonded to only one polymeric strand at a location between the centerline at the second edge.
 20. The absorbent article of claim 10, whereinthe polymeric ribbons are elastic, the polymeric strands are elastic, orboth the polymeric ribbons and the polymeric strands are elastic.